SIN Ein

SINUMERIK 810D/840D/840Di
Beginner’s Manual: Milling and Turning

Edition 10.03
2nd revised edition Oct. 2003
valid for software versions from HMI06.03
All rights reserved

No part of this publication may be copied or distributed, transmitted, transcribed, stored in a retrieval system,
in any form or by any means, electronic, mechanical, magnetic, manual, or otherwise, or disclosed to third
parties without the express written permission of the authors.
This Beginner’s Manual has been created in cooperation of

SIEMENS AG
Automatisierungs- und Antriebstechnik
Motion Control Systems
Postfach 3180, D-91050 Erlangen
and
R. & S. KELLER GmbH
Klaus Reckermann, Siegfried Keller
Postfach 13 16 63, D-42043 Wuppertal
Order No.: 6FC5095-0AB00-0BP1

Preface
The ditigital control systems SINUMERIK 810 D, 840d and 840Di are characterized by their large
"openness", i.e. they can be configured by the machine manufacturer and partially also by the user
himself according to their own requirements. They can thus efficiently be used in many fields of
application both in the small-series production and in fully automatic manufacturing lines.
When creating this Manual, it has been the objective to provide the large range of users an easily
understandable access to these powerful control systems.
The control systems 810D, 840D und 840Di can be used to control many different machining
processes. This Manual deals with the two essential technologies turning and milling.
It has been created in cooperation with NC experts and lecturers. We would like to express our
special thanks to Mr. Markus Sartor for his valuable hints and criticism.
The Manual is practice-oriented and action-oriented. The keys and their use are explained step by
step. The comprehensive presentation of screenshots enables you to compare your own inputs at
the control system with the values and specifications given in this Manual.
This Manual can also be used as a preparation or assessment away from the control system with
the control-identical system SinuTrain on the PC.
The examples of this Manual were created using mainly Software Version 5.2.
Further developments of the software and the already described "openness" of the control system do
not exclude that the operation of your control system differs in certain details from the configuration
described. It might also happen that - in dependence on the position of the keyswitch on the
machine - not all described functions are available. In such cases you are kindly asked to refer to the
documents of the machine manufacturer or to company-internal documents.
We wish you much pleasure and success for the work with your SINUMERIK control system.
The authors
Erlangen/Wuppertal, in March 2001
1
810D/840D/840Di Beginner’s Manual
Table of Contents
1 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Geometric fundamentals of milling and turning . . . . . . . . . . . 5
1.1.1 Tool axes and working planes . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Absolute and incremental dimensions (milling) . . . . . . . . . . . . . . 8
1.1.3 Cartesian and polar dimensions (milling). . . . . . . . . . . . . . . . . . 9
1.1.4 Circular movements (milling) . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1.5 Absolute and incremental dimensions (turning) . . . . . . . . . . . . . . 11
1.1.6 Cartesian and polar dimensions (turning) . . . . . . . . . . . . . . . . . 12
1.1.7 Circular movements (turning) . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Technical fundamentals of milling and turning . . . . . . . . . . . . 14
1.2.1 Cutting rate and speeds (milling) . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 Feedrate per tooth and feedrate (milling) . . . . . . . . . . . . . . . . . 15
1.2.3 Cutting rate and speeds (turning) . . . . . . . . . . . . . . . . . . . . . 16
1.2.4 Feed (turning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Overview of the control system . . . . . . . . . . . . . . . . . . . . 18
2.1.1 Turning on, area switchover, turning off . . . . . . . . . . . . . . . . . . 19
2.1.2 Keyboard and screen layout . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.1 Tool management: Creating a tool and loading it into the magazine. . . . 29
2.2.2 Tool compensation: Creating a tool . . . . . . . . . . . . . . . . . . . . 34
2.2.3 Tools of the sample programs . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.4 Scratching the tool and setting zero . . . . . . . . . . . . . . . . . . . . 40
2.3 Managing and executing programs . . . . . . . . . . . . . . . . . . 43
2.3.1 Saving data to floppy disk and reading them from floppy disk . . . . . . . 43
2.3.2 Enabling, loading, selecting and executing a program . . . . . . . . . . . 47
2
3 Programming: Milling . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1 Workpiece "Longitudinal guide" . . . . . . . . . . . . . . . . . . . . 52
3.1.1 Creating workpiece and part program . . . . . . . . . . . . . . . . . . . 53
3.1.2 Tool call and tool change . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1.3 Fundamental functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1.4 Simple traversing paths without cutter radius compensation . . . . . . . 57
3.1.5 Drilling using cycles and subroutine technique . . . . . . . . . . . . . . 59
3.1.6 Creating a subroutine . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1.7 Simulating a program . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.2 Workpiece "Injection mold" . . . . . . . . . . . . . . . . . . . . . . 73
3.2.1 Creating workpiece and part program . . . . . . . . . . . . . . . . . . . 73
3.2.2 Straight lines and arcs - path milling with cutter radius compensation . . . 75
3.2.3 Rectangular pocket POCKET3. . . . . . . . . . . . . . . . . . . . . . . 79
3.2.4 Circular pocket POCKET4 . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.2.5 Copying a program part . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4 Programming: Turning . . . . . . . . . . . . . . . . . . . . . . . . 90
4.1 Workpiece "Shaft". . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.1.1 Creating workpiece and subroutine . . . . . . . . . . . . . . . . . . . . 91
4.1.2 Tool call, cutting rate and fundamental functions . . . . . . . . . . . . . 98
4.1.3 Face turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.1.4 Cutting cycle CYCLE95 . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.1.5 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.1.6 Error correction - parallel editing of main program and subroutine . . . 104
4.1.7 Thread undercut acc. to DIN76 . . . . . . . . . . . . . . . . . . . . . 105
4.1.8 Thread cutting cycle CYCLE97 . . . . . . . . . . . . . . . . . . . . . 107
4.1.9 Grooving cycle CYCLE93 . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2 Workpiece "Complete" . . . . . . . . . . . . . . . . . . . . . . . . 111
4.2.1 The SINUMERIK contour calculator . . . . . . . . . . . . . . . . . . . 111
4.2.2 Cutting and finishing of the contour with undercut . . . . . . . . . . . . 119
4.2.3 Drilling centrally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.2.4 End face machining with TRANSMIT . . . . . . . . . . . . . . . . . . 121
Appendix
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Commands and addresses discussed in this Manual . . . . . . . . . . . . . . . . 128
Cycles discussed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3
4
1 Fundamentals
This Chapter provides some general geometric and technological fundamentals for the programming of milling
and turning procedures for CNC beginners.
1.1 Geometric fundamentals of milling and turning
The geometric fundamentals presented here refer mainly to the graphical SINUMERIK contour calculator.
The screenshots used in this Manual are intended to support the theory.
To understand the theoretical examples provided by the control already in advance:
Operating area "Program" > Create new part program > Horizontal softkey (Contour) in the text editor
> vertical softkey (Generate contour) > ...
You will find a practical example presenting this contour calculator in the Chapter "Programming/Turning".
1.1.1 Tool axes and working planes
MILLING
On universal milling machines the tool is installed in most cases parallel to the main axes. These axes right-
angled to each other are aligned according to DIN 66217 or ISO 841 to the main guideways of the machine.
The appropriate working plane results from the mounting position of the tool.
The Z axis is mostly the tool axis for milling.
Tool axis Z - working plane G17
If the shown coordinate system is turned correspondingly, the axes and their directions in the associated working
plane will change (DIN 66217).
5
1.1 - Geometric fundamentals of milling and turning
Tool axis Y - plane G18
Note: It may happen with the software

release of your control system that Z is
before X in plane G18 due to reasons
of compatibility. This also refers to
turning (see below).
Tool axis X - plane G19
TURNING
On universal turning machines the tool is installed in most cases parallel to the main axes. These axes right-
angled to each other are aligned according to DIN 66217 or ISO 841 towards the main guideways of the machine.
The Z axis is mostly the workpiece axis for turning.
Rotating axis Z - plane G18 *

Since it is relatively easy to control the diameter of turned workpieces, the dimensions of the transverse axis
always refer to the diameter. Thus, the worker can compare the actual dimension directly with the drawing
dimensions.
Use the key to call approriate help screens to select the

tool axis.
The radius dimension

shown here also exists in
the help screenform, but
it "hardly never occurs".
* All turning operations are programmed in plane G18.

Drilling and milling operations at the end face of the turned part are programmed in plane G17.
Drilling and milling operations at the peripheral surface of the turned part are programmed in plane G19.
6
To enable a CNC control system, such as the SINUMERIK 840D, to orient itself in the existing working area,
there are some important reference points.
Machine zero M
The machine zero M is defined by the manufacturer and cannot be changed. When milling, it is in
the origin of the machine coordinate system, and when turning, on the contact surface of the spindle
nose.
Workpiece zero W
The workpiece zero W, also referred to as the program zero, is the origin of the workpiece coordinate
system. It can also be freely selected and when milling, it should also be located at a position in the
drawing from which most of the dimensions are measured.
When turning, the workpiece zero is always located on the rotary axis and mostly on the plane surface
Reference point R
The reference point R is approached when setting the measuring system, since in most cases the
machine zero cannot be approached. The control system will thus find its reference point in the
position measuring system.
Toolholder reference point T

The toolholder reference point T is important for setting up with default tools. The lengths L and Q
shown in the diagram below are used as tool calculation values and are entered in the tool memory
of the control system.
7
1.1.2 Absolute and incremental dimensions (milling)
Absolute inputs: Incremental inputs:

The entered values refer to the The entered values refer to the
workpiece zero. current position.
* *
By using the softkey ,
you can switch over at any time.
End point End point
Current position
Current position
W
W
*G90 Absolute dimensions *G91 Incremental dimensions

For absolute inputs, the absolute coordinate values For incremental inputs, the difference values
of the end point in the active coordinate system must between the current position and the end point must
always be entered (the current position is not taken always be entered taking into account the direction.
into account).
Two examples of the combination absolute/incremental:
8
1.1.3 Cartesian and polar dimensions (milling)
To define the end point of a straight line, two pieces of data are required, e.g.:
Cartesian: Input of the coordinates X and Y Polar: Input of the length and of an angle
All hidden values are

Note:
calculated and
displayed automa-
tically.
Angle 53.13° = starting angle to positive X axis

or
angle 39.094° = angle to previous element
Cartesian and polar inputs can be combined, e.g.:

Input of the end point in Y and of length Input of the end point in X and of an angle
The context-related help screens can be called during the input; they
display the names of the individual input boxes.
9
1.1.4 Circular movements (milling)
According to DIN, the end point of the arc (coordinates X and Y in the G17 plane) and the center point (I and
J in the G17 plane) have to be indicated for arcs.
The SINUMERIK contour calculator also allows you in case of circular arcs to accept any dimension from the
drawing without much conversion.
In the following you will find an example with two - at first only partially determined - arcs.
Input of the center point (absolute):
After input: After input:
The following values result if you have entered all known dimensions, and if you have pressed the softkey
in the input window of the respective arc.
The inputs of the arcs in the text editor would be:

G2 X22.414 Y58.505 I20 J0 G2 X105 Y70 I=AC(90) J=AC(70)
10
1.1.5 Absolute and incremental dimensions (turning)
Absolute input: Incremental input:

The entered values refer to the The entered values refer to the
workpiece zero point. current position.
Using the softkey , you

can switch over at any time.
* *
End point End point

Attention:
In contrast to DIN 66025 the diameter
related I-values are entered and
Current displayed when having the valid setting
"DIAMON".
position
Current
position
*G90: Absolute dimensions *G91: Incremental dimensions

For absolute inputs, the absolute coordinate values For incremental inputs, the difference values
of the end point in the active coordinate system must between the current position and the end point
always be entered (the current position is not taken must always be entered taking into account the
into account). direction.
Two examples of the combination absolute/incremental:
11
1.1.6 Cartesian and polar dimensions (turning)
To define the end point of a straight line, two pieces of data are required. This data can be as follows:
Cartesian: Input of the coordinates X and Z Polar: Input of the length and of an angle
Note:
All hidden values are
calculated and displayed
automatically.
End point End point
Angle 126.87° = starting angle to positive Z axis

or
angle -39.094° = angle to previous element
.................(39.094° = 360° - 320.906°) 1
Cartesian and polar inputs can be combined, e.g.:
Input of the end point in X and of the length Input of the end point in X and of an angle
The context-related help screens can be called during the input; they
display the names of the individual input boxes.
12
1.1.7 Circular movements (turning)
According to DIN, the end point of the arc (coordinates X and Z in the G18 plane) and the center point
(I and K in the G18 plane) have to be specified for arcs.
The SINUMERIK contour computer also allows you in case of arcs to accept any dimension from the drawing
without much conversion.
In the following you will find an example with two - at first only partially determined - circular arcs.
Input of arc R10: Input of arc R20:
After input: After input:
The following values result if you have entered all known dimensions, and if you have pressed the softkey
in the input window of the respective arc.
The inputs of the arcs in the text editor would be:

G2 X50 Z-35 CR=10 G3 X30 Z-6.771 I0 K-20
13
1.2 - Technical fundamentals of milling and turning
1.2 Technical fundamentals of milling and turning
1.2.1 Cutting rate and speeds (milling)
The optimum speed of a tool in each individual case depends on the cutting tool material grade, the material
of the workpiece and the tool diameter. In the practice, this speed is also often entered immediately without any
calculations, based on many years of experience. The better way, however, is to calculate the speed from the
cutting rate specified in the appropriate tables.
Determination of the cutting rate:
First, determine the optimum cutting rate on the basis of the manufacturer catalogs or a table book.
.
Cutting tool material grade: Workpiece material:

Hard metal C45
vc = 80 ... 150 m/min:

The mean value vc = 115 m/min should be selected.
Calculating the speed:

Use this cutting rate and the known tool diameter to calculate the speed n.
v c ⋅ 1000
n = ----------------------
-
d⋅π
The example below shows how to calculate the speed for two tools:
d1 = 63mm d2 = 40mm
115mm ⋅ 1000- 115mm ⋅ 1000-

n 1 = --------------------------------------- n 2 = ---------------------------------------
63mm ⋅ π ⋅ min 40mm ⋅ π ⋅ min
1 1 (in the workshop also often referred to

n 1 ≈ 580 ---------- n 2 ≈ 900 ---------- as r.p.m.)
min min
The NC coding uses the acronym "s" for the speed.
In this case, the inputs will be S580 and S900.
With these speeds, the cutting rate of 115 m/min is achieved.
14
1.2.2 Feedrate per tooth and feedrate (milling)
On the previous page, you have learned how to determine the cutting rate and how to calculate speeds.
To make sure that the tool cuts, a tool feedrate must be assigned to this cutting rate or speed.
The basic value of the feedrate is the characteristic quantity "feed per tooth".
Determining the feed per tooth:

Like the cutting rate, the value for the feed per tooth is also determined using either the table book or the
appropriate documents of the tool manufacturer.
Hard metal C45
Feed per tooth fz = 0.1 ... 0.2 mm:

The mean value fz = 0.15 mm should be selected.
Determining the feedrate:

The feedrate vf is calculated using the feed per tooth, the number of teeth and the known speed.
vf = fz ⋅ z ⋅ n
The example below shows how to calculate the feedrate for two tools with a different number of teeth:
d1 = 63mm, z1 = 4 d2 = 63mm, z2 = 9
1 1
v f 1 = 0, 15mm ⋅ 4 ⋅ 580 ---------- v f 2 = 0, 15mm ⋅ 9 ⋅ 580 ----------
min min
mm mm
v f 1 = 348 ---------- v f 2 = 783 ----------
min min
The NC coding uses the acronym "F" for the feedrate.

In this case, the inputs will be rounded off F340 and F780.
With these feedrates, the feed per tooth of 0.15 mm is achieved.
15
1.2 - Technical fundamentals of milling and turning
1.2.3 Cutting rate and speeds (turning)
Unlike milling, turning generally calls for the desired cutting rate to be programmed directly, namely when
roughing, finishing and plunge-cutting.
Only when drilling, and (in most cases) when thread cutting, is the desired speed programmed.
Determining the cutting rate:
First, determine the optimum cutting rate on the basis of the manufacturer catalog or a table book.
.

Hard metal Free-cutting steel
vc = 180 m/min:
Constant cutting rate vc (G96) when roughing, finishing and plunge-cutting:
To make sure that the selected cutting rate is observed on each workpiece
diameter, the appropriate speed is adapted by the control system using the
command G96 = constant cutting rate. This is carried out using either d.c.
motors or variable-frequency three-phase motors.
With reduced diameter, the speed theoretically increases infinitely. To avoid
hazards from excessive radial forces, a speed limit, e.g. of 3,000 r.p.m. must
be programmed.
In this case, the inputs will be G96 S180 LIMS=3000.
Constant speed n (G97) when drilling and thread cutting:

Since the speed is constant when drilling,
v c ⋅ 1000 the command G97 = constant speed must
n = ----------------------
- be used here.
d⋅π
The speed is dependent on the desired
d = 20mm (tool diameter) cutting rate (120 m/min is selected in this
case) and the tool diameter.
120mm ⋅ 1000
n = ---------------------------------------- In this case, the inputs will be G97 S1900.
20mm ⋅ π ⋅ min
1
n ≈ 1900 ----------
min
16
1.2.4 Feed (turning)
On the previous page, you have learned how to determine the cutting rate and how to calculate speeds.
To make sure that the tool cuts, a tool feedrate must be assigned to this cutting rate or speed. The basic value
of the feedrate is the characteristic quantity "feed per tooth".
Determining the feed:

Like the cutting rate, the value for the feed is also determined using either the table book or the appropriate
documents of the tool manufacturer or else is based on empirical knowledge.

Hard metal Free-cutting steel
Feed f = 0.2 ... 0.4 mm:

The mean value f = 0.3 mm should be selected (in the workshop often referred to as mm per rev.).
In this case, the input will be F0.3.
Interrelation between feed and feedrate:
The constant feed f and the appropriate speed results in the feedrate vf.
m m
v c = 180 ---------- v c = 180 ----------
min vf = f ⋅ n min
d = 80mm d = 20mm
2 1
1 1
n 2 ≈ 710 ---------- n ≈ 2800 ----------
min 1 min
1 1
vf = 710 ---------- ⋅ 0, 3mm vf = 2800 ---------- ⋅ 0, 3mm
2 min 1 min
mm mm
v f 2 ≈ 210 ---------- vf = 840 ----------
min 1 min
Since the speed is different, the feedrate on the

different diameters is also different (despite the
same programmed feed).
17
2.1 Operation - Overview of the control system
2 Operation
In this manual for beginners the general term "operation" is used for all operating sequences which take place
in the direct interaction between user and machine. After a fundamental introduction in Section 2.1, the second
subsection deals with setting up tools and workpieces. The third and fourth subsections deal mainly with the
production, i. e. the execution of NC programs.
The control systems 810D/840D/840Di are based on an open control concept which allows the machine
manufacturers (and partially also you as the user) to configure the control system according to individual
requirements. That’s why it is possible that there will be differences in the manual as regards the sequences
of action. Please, follow the instructions of the machine manufacturer if necessary, and carefully check your
inputs before you start the machine.
2.1 Overview of the control system

In this section, you will learn something about
structure and handling of the control system
components "keyboard" and "display".
Pictures:
• OP 010C operator panel front with
TFT color screen, softkey bars (horizontal und
vertical) and mechanical CNC full keypad with 65
keys.
These components are used mainly for the

programming and processing of data.
• Machine control panel with

override potentiometers
This control panel influences the machine movements

directly.
To a certain degree, it can also be configured by the
machine manufacturer according to the customer’s
requirements.
For further operating components for the control system and training keyboards for SinuTrain,
please refer to the catalog NC60 "Automation systems for machine tools"
(SIEMENS order no. E86060-K4460-A101-A8-7600).
18
2.1.1 Turning on, area switchover, turning off
Depending on whether you train yourself directly on the machine or whether you use the control-identical
Sinumerik training system on the PC, you have to start your work in a different way.
Turning on
If... you are working on the If ... you are working on the Windows PC:
machine:
Then, of course, first you will Then you will start the software
have to look for the main switch via the icon on the desktop or via
located either on the side of the the entry in the start menu
machine or on the control (Start > Programs > SinuTrain ...
cubicle. > SinuTrain START).
Then you can choose between

the two technologies (milling/
turning) and the kind of tool
management (see Sections
2.2.1 and 2.2.2).
(With Software Version 6 and
higher, machines can also be
configured according to the
customer’s requirements).
After turning on, the control

system is in the "Machine" After having started the
operating area, and the "Ref" software, the "Machine"
function (reference point operating area is active and the
approach) is selected. "Auto" mode is selected.
The way how to approach the
reference point depends on the A reference point approach will not be
machine type and the machine simulated on the PC.
manufacturer and can
The "JOG" mode for direct selection of
therefore not be be discussed
traversing axes is not functional on the
here in detail.
PC.
19
Area switchover
Keys/inputs Screen / drawing Description
By using the <Area switchover key> ( on the slimline operator panel or on the PC
keyboard), you can - independent of the operating situation you are currently in - unhide
the main menu with the six opreating areas of the control system.
The main menu is displayed in the

active Machine operating area. The
softkey of the active operating area is
selected.
In this operating area, you will control
the machine directly. Here you can
traverse manually, scratch, or run NC
programs.
Example: Machining center with three linear axes

(X, Y, Z) and 2 rotary axes (A, C)
Change with the softkey to the

Parameter operating area.
This can be done on the slimline
operator panel via the appropriate
softkey. On the PC, you can click the
softkey with the mouse or call the
operating area panel with .
The Parameters operating area is
intended, e.g. to manage your tools
and the table of zero offsets.
Example: Magazine list on a turning machine with

tool management
Active operating area ’Program

(called via softkey, via mouse or ).
In this operating area, you write and
simulate NC programs.
The Chapters 3 (milling) and 4 (turning)
explain this in detail.
20
Active operating area Services

In this operating area, you can manage
files and read them in and out via the
serial interface or a floppy disk.
Active operating area Diagnosis

Alarm and and service information are
displayed and documented here.
Active Coperating area Start-up

As the name already tells, this
operating area is intended for system
engineers in order to adapt NC data to
the machine.
It is hardly of any importance in the
daily use and will therefore not be
discussed in detail in this Manual.
Example: Turning machine with two spindles
( ) Depending on the configuration of your system, the

(...) 7th or 8th softkeys of the main menu can also be
labeled; you can use them to call other applications
(e.g. AutoTurn).
21
( ) By pressing the <Area switchover key> ( ) repeatedly, you are able to go back and
forth between the two operating areas last active what is quite useful, e.g. when
programming to see the tool data in parallel.
Just try it with both operating areas "Program" and "Parameters".
The "etc. arrow" down on the right

indicates that there are other functions
or applications.
By pressing the key on the slimline

operator panel or + on the PC *,
you can extend the menu, and the
softkeys are reassigned - differently
according to the configuration -
hold down * , then
Pressing the key once again brings you

back to the main menu of the operating
areas.
Turning off
If ... you work on the machine: If ... you work with SinuTrain on the PC:
Please, observe the ( ) On the extended main menu bar, you

instructions of the machine will find a softkey to exit SinuTrain!
manufacturer! ( PC keyboard: > + > )
Trip the main switch to When quitting the software, all user
disconnect the system from the data are automatically stored for the
mains. next session.
(Alternatives: , see page 26.)
2.1.2 Keyboard and screen layout
During your first contacts with the user interfaces of the control systems, you have already learnt something
about the key <Area switchover> ( ), the <etc.> key ( ) and the horizontal softkeys of the main menu. In
the following, further important keys are introduced to you (using the example of the SinuTrain training
keyboard "QWERTY" and the control system screen.
22
All keys of the slimline operator panel and of

the CNC keyboard are integrated in the shown
training keyboard, and in addition, you will also
find here the most important keys of the
machine control panel, which are also used on
the PC.
All functions required for working with SinuTrain

can be operated directly or via key combinations
with a normal PC keyboard. They are listed in
the following table. 2
Slimline operator panel
Key PC keys Description
... By using the horizontal softkeys (numbered from the left to the right), you
change between the operating areas. Within one operating area, you get
into further menu areas and functions which can be called via the vertical
softkeys.
+ * By using the vertical softkeys (numbered from the top to the bottom), you
: activate functions or branch to further subfunctions which are called via
+ * the vertical softkey bar.
By using the <Area switchover> key, the main menu with the operating
areas is displayed.
+ * By using the <etc.> key, you extend the horizontal softkey bar.
+ * By using <Machine area key>, you can go directly to the operating area
"Machine".
The <Recall> key closes the window on top and lets you return to the
higher-level menu. This function is always available if the key symbol
above the first horizontal softkey is displayed.
Hold down * , then press the appropriate <F> key.
23
CNC full keyboard
Keys PC keys Description
The numeric keygroup is used to enter digits and basic arithmetic

operations.
In combination with the <Shift> key (see below), you can enter special
characters (?, & ...).
By using the "QWERTY" keyboard, you enter, e.g. names of part

programs and naturally also NC commands.
(The name "QWERTY" arises from the arrangement of the keys.
The so-called "DIN" keyboard with alphabetic allocation is often installed
at turning machines; the function is identical.)
<Space key> to produce space characters
By pressing the<Shift> key, you can call the upper characters on double-
assigned keys and write capital letters (see above).
By using the <Input> key, you can accept an edited value, open a list or
a file or select the end of a program line in the editor and go with the
cursor to the next, new line.
Practical You want to enter the following NC block in the control system: G0 X40 Z-3.5
example:
+ According to the configuration of your control

system ...
+ • ... only capital letters (also without <Shift>
key) are written.
+
• ...the <Shift> key can - unlike the PC - already
be released before pressing the letter key.
Each NC block is accepted by pressing <Input>.
The use of capital letters and the clear structure of the inputs by space
characters is common and advisable. But the control system also
"understands" this input: g0x40z-3.5
This key acknowledges and clears the alarm selected by this symbol.
24
The display of the "i" symbol in the dialog line shows that you can call
further explanations on the current operating status by using this
information key. The "online help", for instance, is especially useful for
certain NC commands. (see page 76).
If several windows are displayed on the screen, only one of them has got
the focus; you can see this by the window frame having a different color.
With the help of this key you can go from one window to the next
(alternative: mouse click into the window). Key inputs always refer only
to the window with focus!
The keys <Page Up> und <Page Down> are used to move the scrollbar
of a window, allowing you to scroll, e.g. through long part programs.
By pressing this key, you move the cursor to the end of the line.
You can move the cursor with the four <arrow keys> .
By pressing the <selection key> or the <toggle key> ( or on the
numeric keygroup with "NUM LOCK" switched off), you activate or
deactivate a field or select in input fields (if you can see the toggle symbol)
one of various options (alternative: mouse click).
By pressing the <Delete> key, you delete the selected character or the
value of an input field.
You delete the character left of the cursor with the <Delete key>
(<Backspace>).
Practical You have entered the NC block G1 X0 F0.2 and completed with <Input>. Now you
example: want to change the feedrate to 0.3. This can be done using various possibilities:
1st possibility:
Since the last character has to be replaced here,
it is useful to go directly to the end of the line with
<END> and to delete the 2 (the character left of
the cursor) with <Backspace>.
... 2nd possibility:

Alternatively, you can move the cursor to the right
character by character, and if the cursor is on
the 2, you can delete it with <DEL>.
25
In the input fields, you can use the <Edit> or <Undo> key to switch over
to the editing mode (see practical example).
If you want to undo an erroneous entry in the editing mode, then press
again. The overwritten entry will be recovered.
Practical You want to change the value -82.47 to -82.475 in the input field without entering the
example: whole digit once again. The value to be changed is selected ( ).
Enable editing mode.

... Position cursor.
Add digit 5.
Accept changed value (the orange selection changes
to the next input field.)
Machine control panel
Key PC key Description
+ + The key <NC Start> is intended mainly to start the execution of programs.
+ *
+ + By pressing the key <NC Stop>, you stop the execution of the current
+ * program. Then you can continue the execution of the current program in
the current block by pressing <NC Start>.
+ + By pressing the <Reset> key, you interrupt the program execution,

+ * messages are cleared (see also ), and the control system is reset to
its initial state (ready for a new program execution).
+ + The key <Single block> allows you to execute a program block by block.
+ * The program execution stops automatically after each block and can be
continued with <NC Start>. Pressing <Single block> again lets you return
to the following block.
+ + + / / * Each of these buttons activates the operating

mode of the same name: AUTO, MDA, JOG.
(in SinuTrain-Standard, only AUTO is
operational).
+ + + / / * Use these buttons to switch the spindle on and off

(not operational in SinuTrain-Standard).
+ + The <EXIT> button is only available on the training keyboard. This stops
+ * and exits from the software program (softkey alternative available).
* Always press the keys one after the other as shown here and then hold them down!
26
Screen layout
8 Channel status messages (e.g. "Stop:

EMERGENCY STOP active" or "Wait: Dwell time
active")
9 Channel status display (e.g. ROV: The over-

ride for the feedrate is also effective for the
rapid traverse feed, SBL1: single block with stop
after each machine function block.
10 If the symbol is displayed, additional

help features can be called (see key on the
CNC full keyboard).
11 In the middle area of the screen, there are

operating windows, according to the operating
1 The current operating area (machine, parameter... is area (e.g. program editor) and/or - as in this case
shown here). - NC displays (position, feedrate, ...).
2 Channel status (reset, interrupted, active) 12 Only one operating window has got the fo-
cus. It is marked by a different color. In this win-
3 Program status (interrupted, running, stopped)
dow, inputs are possibly active (see also key).
4 Channel name (in SinuTrain, the selected technol-
13 Here you will find instructions for the opera-
ogy is displayed here, e.g. ’SinuTrain_Mill’)
tor (if any).
5 Alarm and messages are displayed in this field, to-
14 The Recall symbol indicates that you are
gether with a number under which further explanations
in a submenu and that can you quit it by pressing
can be read in the documentation.
the key.
15 The etc. symbol indicates that there are

6 Mode (AUTO, MDA, JOG) in operating area
further functions which you can display by pres-
"Machine". (The training software SinuTrain includes only
sing the key in the horizontal softkey bar.
the mode AUTO.)
16 Horizontal softkeys: Here you will find the
7 Path and program name of the selected program
operating areas or main functions.
17 Vertical softkeys: Here you will find subme-

nus
and functions.
27
2.2 Operation - Setting up
2.2 Setting up
In this section, you will learn fundamental sequences
of operations required to set up SINUMERIK control
systems 840D/810D/840Di.
Using a milling machine in the configuration "with tool
management"*, you will learn ...
• how to create a new tool in the tool management
• how to "install" it in the real magazine and in the

magazine image of the control system (Section
2.2.1).
Machines with a simple "Tool compensation" naturally

also manage tools, not with names, but via
T numbers.
Especially with turning machines where all tools are
clearly arranged on the turret, this easier configua-
ration is easy to use in practice.
This configuration "with tool compensation"* is
described in Section 2.2.2.
Section 2.2.3 lists all tools which will be used in the following sample programs,
and Section 2.2.4 deals with scratching and zero setting.
* The procedure can be transferred to the correspondingly other technology without any problem.
28
2.2.1 Tool management: Creating a tool and loading it into the magazine
Supposed you have a machining center with a (chain) magazine. You want to create a 63 milling head in
the tool management and load it into any of the free magazine locations.
First, mount the tool manually in the spindle. When doing so, observe the instructions of the machine
manufacturer. Then turn again to the control system screen.
Creating a tool
( ) Call the "Parameters" operating area in

the main menu.
By default, the tools are shown in the

"Magazine list", sorted according to
ascending location numbers.
The horizontal softkey bar changes: In

addition to the presentation of the
"Magazine list", the presentation of the
"Tool list" is now also available.
29
In the "Tool list", the tools are sorted

according to their T numbers.
Using the vertical softkey, you will

create a new tool.
FM63 Enter the name of the new tool (e.g.

"FM63" for a facing tool with ø63mm).
Accept this entry.
Go on with the "Type" list box.
At present, the type "120 End mill" is

selected.
... Open the list box with and select
the type "140 Face mill".
Accept the selected type.
30
A facing tool has been created.

It has got one defined cutting edge D.
Use the appropriate softkey to change

to the next window for the offset values
of this cutting edge.
134.26 If you have measured the offset value

for the length by using a tool-presetting
station beforehand, you can enter it
31.5
here.
The radius of a 63 milling head is
31.5...
[If you find out - when measuring

again - that a tool runs out you can
enter this difference in the line "wear".
The "ideal" dimensions will not be
changed.
If necessary, the length of an adapter
(used for several tools) can be entered
in the "Base" column. This size will be
added to the tool length.]
31
The tool data are complete.

Back to the tool list.
A T number was automatically

assigned to the tool.
But in the program, it will be easily
called via its - more meaningful - name
(see Chapters 3 and 4).
If ... you want to change the data of a tool later ...
Select the line of the appropriate tool in the tool list.
Use the softkey [Tool details] to open the input field for the tool data.
... Implement the changes.
Press the softkey [<<] to close the input box and to return to the tool list.
Loading the magazine
Select the line of the tool which you

want to load into the magazine.
The fields MN (magazine number) und Pl (location) are still free. This means that the
tool is in the tool cabinet and has to be loaded into the magazine....
By using the horizontal softkey, you call

the function for loading.
32
If ... you want to set down the tool If... you have got e.g. a big "confused"
on a certain magazine place ... magazine ....
... you can enter the data ... it is easier if the control system
manually: proposes an already unused magazine
location:
Start the loading process via the

softkey.
The tool will be loaded into the
magazine.
Back to the upper menu level of the

operating area
33
2.2.2 Tool compensation: Creating a tool
Now, the way of the easy tool management: Your SINUMERIK control system manages T numbers and
no tool names. Supposed you have a turning machine and you want to set down a 3mm recessing tool on
the turret location 5.
( ) Call the operating area ’Parameters’ in

the main menu.
By default, the compensation data of

the first tool (T1) are displayed.
You can navigate in the compensation
data list via the vertical softkeys and
execute changes:
Use these softkeys to go from one tool to the next with

the next higher or lower T number.
Use these softkeys to navigate between several

cutting edges of a tool.
Use this softkey to delete a tool or a cutting edge.

Dots in the softkey generally indicate that there will be
still an inquiry or that a submenu exists.
Use this softkey to change to a certain cutting edge

of a certain tool.
Use this softkey to go to the overview list of all tools

(see below).
Use this softkey to create a new tool or a new cutting

edge.
34
In this overview list you can see that the

T number 5 has not yet been assigned.
Use the appropriate softkeys to create

a new tool.
(5) If you have an older software version

you have to enter the T number
manually. If you enter a number
already assigned then this is indicated
as a note.
With Software Version 6.0 and higher,
the first free T number is entered
automatically.
Each type of tool has got a number. The first digit classifies the group of tools:
1xx - milling tools
2xx - drilling tools
4xx - grinding tools
5xx - turning tools
7xx - special tools
The field is assigned the number 220 for the type "center drill" by default.
35
If you have not yet known the If If you know the type number for the
type number for the "recessing "recessing tool"...
tool"...
... you can select the type from ... you can enter the number directly:
the list:
At the same time, the list box 520 Already when entering the first digit, the
with the tool groups will be list box of the turning tools will be
opened when deleting the opened automatically for orientation.
default number.
Of course, you can use both described

ways to deal with a list box also in
combination.
Select the group "5xx turning Just try several ways how to enter in
tools" and accept the selection. order to get used to it.
...
... Select the type "520 Recessing

tool" from the list in the same
way you did before.
The tool type was selected; next

subject is the cutting edge ....
( ) A help screen is provided for the cutting

edge position list box, which you can
call with .
36
3 At first, enter the compensation values

for the left edge (D1).
93.1 If you have measured the compen-

sation values by using a tool presetting
station, you can enter them here.
Example:
42
Length1 (D1) 93.1
Length 2 (D1) 42
Radius of the edge: 0.1
0.1
Now we come to the second edge (D2):
Code number of the second edge: 4
Length 1 (D2) as D1
Length 2 (D2) 39
39 Radius of the edge: as D1
. The width of the recessing tool results

from the difference of the two values for
"length 2": 42 mm - 39 mm = 3 mm.
All compensation values for the tool are

entered. Now, the tool can be selected
in the program with the command T5
(see Chapters 3 and 4).
Back to the higher-level menu!
Now you can create all tools you need for the sample
programs according to the procedure you did before...
37
2.2.3 Tools of the sample programs
In the previous sections, you created both one milling and one
turning tool as an example. The sample programs of the Chapters
3 and 4 use the following tools. In order to be able to carry out these
programs with the help of the simulation diagrams, you have to
create these tools also in the operating area "Parameters".
(Of course, you can also use your "own" tools of the same type with
different names. When programming remember the changed
names for calling the tools.)
Tools in the milling programs
Type Name Cutting data (extract)
140 Face mill SM60 D1 Radius 30

120 End mill EM20 D1 Radius 10
220 Centre drill CD12 D1 Radius 6 *
200 Twist drill TD8_5 D1 Radius 4.25 *
200 Twist drill TD10 D1 Radius 5 *
240 Tap, regular T_M10 D1 Radius 5 *
* Depending on the particular software version, the radius of a drill can be entered only by direct editing of the tool
initialization file. If you are not familiar with it, you should create drills for the simulation as end mills!
There are the following types of tools available for milling:

110 Ballhead cutter 120 End mill 121 Shaft Mill with edge rounding
130 Anglehead cutter 131 Anglehead cutter w. corner rounding140 Face mill
145 Thread cutter 150 Side mill 155 Bevelled cutter
200 Twist drill 205 Solid drill 210 Boring bar
220 Centre drill 230 Countersink 231 Counterbore
240 Tap, regular 241 Tap, fine 242 Tap Withwirth thread
250 Reamer 700 Groove saw 710 3D probe
711 Edge probe 720 Directional probe... 900 Special tool
38
Tools in the turning programs
When creating turning tools, in addition to the cutting edge radius

and the length compensations which you can determine by
scratching or using the tool presetting station, the cutting edge
position also plays an important part.
That’s why you will find the cutting edge position help screen for
your orientation.
Type Name Cutting data (extract)
500 Roughing tool RT1 D1 Radius 0.8 Cutting edge pos. 3

500 Roughing tool RT2 D1 Radius 0.8 Cutting edge pos. 3 clear. angle 44° **
510 Finishing tool FT1 D1 Radius 0.4 Cutting edge pos. 3
510 Finishing tool FT2 D1 Radius 0.4 Cutting edge pos. 3 clear. angle 44° **
540 Threading tool THREAD D1 Cutting edge pos. 8
520 Recessing tool GT_3 *** D1 Radius 0.1 Cutting edge pos. 3 Length 2 e.g. 42
D2 Radius 0.1 Cutting edge pos. 4 Length 2 e.g. 39
200 Twist drill TD5 D1 Radius 2.5 * ****
205 Solid drill SD16 D1 Radius 8 * ****
* Depending on the particular software version, the radius of a drill can only
be entered by direct editing of the tool initialization file. If you are not used
to it you should create the drill for the simulation as an end mill.
** If, when creating a tool, a "clearance angle" or "tool clearance angle" not
equal to 0 is entered this is monitored for collosion when turning undercuts
(see example in Section 4.2).
*** This tool was discussed in Section 2.2.2.
**** If you drill in the G17 plane (recommended), length 1 refers to the Z
axis in the tool compensation, deviating from the compensation values of
the turning tools (see Chapter 5 of the Operator’s Guide)
The following tool types are avaliable for turning:

500 Roughing tool 510 Finishing tool 520 Recessing tool
530 Parting tool 540 Threading tool 730 Stock stop
In addition, there are the drilling, milling and special tools which have already been mentioned on page 38 (milling tools).
39
2.2.4 Scratching the tool and setting zero
When scratching you carefully traverse a tool gauged beforehand to the workpiece until this "scratches". The
control system can calculate the zero offset which the coordinates of the NC program are related to on the
basis of the tool compensation data and the current position of the toolholder.
Scratching and setting zero of the workpiece is a direct interaction of control and machine or of tool and
clamped workpiece. The function "Scratching" is therefore not simulated in the training software
SinuTrain.
Change to the main menu of the control

system and call the operating area
"Machine".
(Alternatively: Key )
( ) Traverse the tool e.g. in the "Jog" mode "manually"

(e. g. with the axis keys of the machine control panel)
( ) to a position which enables a collision-free tool
change (turret swivel).
Activate the tool with which you want to

scratch the workpiece (e.g. by writing a
little program in the mode "MDA"
carrying out the tool call and which
... causes the spindle to rotate).
Start the program with the key
<NC Start> on the machine control
panel.
Then change again to the manual

mode (JOG mode) (without using
<Reset> or <NC Stop> in the
meantime).
40
Here you can activate the function

"Scratch" via a horizontal softkey.
G54 In the function window you determine

in which zero offset (G54, G55, ...) you
want to store the result.
Then position the cursor (with <Arrow
down>, not with <Input>!) on the input
field "Setpoint position" for the axis in
which you want to scratch at first (here
Z axis in turning).
Traverse the tool carefully with the axis keys, a

separate handheld unit or electronic handwheels until
it comes into contact with the workpiece. (If
necessary, you can then retract the tool vertically to
the scratching direction and stop the spindle).
1 In the field "Setpoint position", enter the

value which you wish this coordinate to
have later in the program. When doing
so, take into account the length
compensation of the tool (see help
screen below).
The offset is displayed on the left next
to the input field.
The length compensation of the tool in Z ("length 2")

is opposite to the axis.
The geometry of the tool is thus considered negatively
when calculating the offset.
This is done by switching over to "-" in the field after
the setpoint position.
41
... If necessary, determine the zero offset

for the remaining axes in the same way
(for turning, it is not necessary,
because the turning center has always
got the X value 0).
Finally accept all values in the selected

zero offset, in this case G54.
You can "read again" all zero

offsets of the control system in
the "Parameters" operating
area.
The zero offset becomes active when calling the

appropriate command (G54, G55, ...) in the NC program.
42
2.3 Managing and executing programs

This section deals with swarf and swarf removal.
Provided that there is already an executable and tested program

(see Chapters 3 and 4 regarding programming) ...
... then you will learn here how you can load it from a floppy disk
into the control system, from the program management into the
kernel of the control system and finally execute it.
2.3.1 Saving data to floppy disk and reading them from floppy disk
Your SINUMERIK control system offers you several opportunities to read in and read out data. You can select
them in the operating area "Services" via the vertical softkey bar:
[V24 ] Serial interface [PG] Programming device
[Disk... ] Floppy disk drive [Archive... ]Archive directory on the hard
disk
The data exchange between control system and floppy disk will be discussed in the following. Insert a
formatted, non write-protected floppy disk.
Control system -> floppy disk (reading out)
The basis of this example is any

workpiece directory (here
"TEST.WPD") you have created in the
operating area ’Program’ and to which,
e.g. a part program
("PILOTPROGRAM.MPF") and a
subroutine ( "UP20.SPF") belong.
You find a detailed example regarding the creation of workpiece directories and
programs in Section 3.1.
43
2.3 Operation - Managing and executing programs
( ) Change to the main menu of the control

system and call the operating area
"Services".
The window displays the directories

(type "Dir" for "Directory") which can
also be selected in the operating area
"Program" via the horizontal softkeys.
This means the workpiece directory
"TEST.WPD" is in the list
"Workpieces.DIR":
Open the higher-level workpiece

directory....
...
... and select the directory you want to

store on the floppy disk (here also
...
"TEST.WPD").
In the display of the softkey [Data in],

the softkey is marked to be active.
By using the softkey [Data out] you

switch over to data ouptut.
44
The window shows the contents of the

floppy disk. The field "Archive name"
has the focus; it is already assigned the
workpiece name by default.
If ... you want to know before saving which data have already been stored on the floppy
disk .....
You advance the focus with the <Tab>-

key or the <END> key until the orange
bar has marked a line in the file list.
You can move the cursor in the file list

... with the keys <Arrow down> and
<Arrow up>. The name of the selected
file is accepted into the field "Archive
name" (and it would possibly be
overwritten!).
Switch the focus back to the field

"Archive name" with <Tab> and enter
the name of the workpiece again.
Start loading of the data from the

control system to the floppy disk.
The loading process is logged in the
notice line. If data have been
successfully loaded, the message "Job
completed" is displayed.
Open now the workpiece directory

"TEST.WPD", select part program
"PILOTPROGRAM.MPF" ...
... and load it separately as an exercise

once again to the floppy disk.
45
Then, change into the menu [Manage

data] and ask for the content of the
[Disk].
The workpiece directory "TEST.WPD"
was stored as "TEST.ARC" with the
data contained therein.
The program file "PILOT-
PROGRAM.MPF" was stored as
"PILOTPROGRAM.ARC" .
Background:
The extension "ARC" stands for ’archive’. The complete data structure with workpiece
directory, part program and subroutine is kept within the archive file "TEST.ARC.
This structure will be recovered when restoring an ARC file.
Quit the menu with the <Recall>

key.
The cursor selects the file which
was just copied to the floppy
disk.
Floppy disk -> control system (reading in)
Select now the menu for reading in

data.
The part program which was

stored as
"PILOTPROGRAM.ARC" on the
floppy disk is to transfer back to
the control system.
46
Select the file

... "PILOTPROGRAM.ARC" from the file
list of the floppy disk ...
... and start the transfer.
Because the original part program still

exists on the control system, you will be
asked once again whether you want to
overwrite it.
Answer this question with [Yes].
The file will be replaced by its own copy.
2.3.2 Enabling, loading, selecting and executing a program
If a program is not yet completed or if it has still to be tested, you can withdraw its "release", preventing it
from being loaded, selected and executed.
In order to execute a program, it must be in the NC main memory. If the control system possesses a hard
disk, this is carried out using the "Load" function. Because the memory capacity of the NC main memory is
limited, you should unload programs you temporarily do not need, i.e. to store them back to the hard disk (if
any).
One of the loaded programs can be selected for execution. This is done using the "Select" function. The
name of the selected program is shown in the top right of the head line of the screen.
Before you start a program you should remember the following things:
Check carefully using the simulation whether the

program is error-free.
We do not assume any warranty for the sample
programs in this Manual.
Especially cutting data (speed, feedrate, cutting
width) have possibly to be adapted to the
conditions of your machine.
47
Make sure that all tools used in the program are

available in the magazine or in the turret and that they
are gauged correctly!
Make sure that the workpiece was clamped reliably

and that the zero point has been set correctly!
Under certain circumstances it is advisable to carry
out first a dry run of the program, i.e. without
workpiece in order to test all programmed movements
for collision once again.
Set the feed override before the first test run of a

program to ZERO just to have enough time also to
intervene later in case of incorrectly programmed
rapid traverse motions.
In especially critical places, you should switch over to

single block mode.
48
Now we come to a concrete example: You have programmed the workpiece "Complete" in the operating area
"Program" or you have loaded the program data in the operating area "Services", e.g. from floppy disk.
Change to the operating area

"Machine".
If another mode is active, then activate

( ) the mode "AUTO".
( )
Open the program overview ...
... and select the workpiece

...
(directory) COMPLETE.
The workpiece is already released.
Just to exercise you can ...

• withdraw the workpiece release, ...
• try to load it (in vain) ...
• acknowledge the message...
• and finally release the workpiece.
49
Now load the workpiece into the NC

main memory.
If you open the workpiece directory with

<Input>, then you will see that all
programs included therein (part
program "COMPLETE.MPF", as well
as subroutines COUNTUR.SPF" and
"TCP.SPF") have also been loaded
when loading the directory.
The configuration of the simulation is
stored in the file DPWP.IN. It is not
needed for the machining on the
machine and is therefore also not
loaded.
If workpiece list and part program If the part program to be processed has
have got the same name as it a different name than the workpiece
is here the case... directory (e.g. because the part has to
be machined from two sides and you
have therefore created two main
programs called "SIDE_1" and
SIDE_2")...
... the part program having the ... ... select the part program (type "MPF")
same name (type "MPF") will in the workpiece directory and then
be loaded by the "selection" of press [Selection].
the workpiece (type "WPD").
The name of the selected program will now appear in the head line of the screen:
50
Quit the program overview by pressing

the key <Recall>.
Now you can see the "Current block"

(i.e. the first one) of the selected
program in the window marked in
yellow.
Alternatively, it is also possible to

display the whole program in this
window.
(With [Program blocks] and [Program
sequence], you can change between
these two displays.)
You have various possibilities of

influencing the execution of the
program.
The status is displayed in the status bar
...
in the top of the screen.
Whenever you wish, you can activate
or deactivate the active single block
mode (SBL1, SBL2 or SBL 3) by using
the key <SingleBlock> on the machine
operator panel.
Start the program.
When running the program for the first

time, carefully increase the feed
override.
In critical situations:
or in the worst case !
51
3.1 Programming: Milling - Workpiece "Longitudinal guide"
3 Programming: Milling
In this chapter you will learn how to program the
control systems SINUMERIK 810D/8450D/840Di,
using the example of two simple sample workpieces.
Of course, not everything will be discussed

here what is possible to do with these powerful
control systems. But, if you have programmed
these both workpieces, then you will be able to
start working without any help.
3.1 Workpiece "Longitudinal guide"

Using the workpiece "Longitudinal guide" as an example, you will learn the complete way from the
drawing to the finished NC program key by key. In this context, the following topics will be discussed:
• Structuring into workpiece, part

program and subroutine
• Tool call and tool change
• Fundamental functions
• Technological functions (cutting

data)
• Simple traversing paths without

cutter radius compensation
• Drilling with cycles and subroutine

technique
• Simulation to check the

programming
52
3.1.1 Creating workpiece and part program

Keys / inputs Screen / drawing Description
Initial status:
• Any operating area (here
"Machine") and mode (here
"AUTO")
• Channel status RESET, i.e. no

( ) program is currently executed.
If not yet done, press the <Reset>
key to reset the control system
(see status bar in the top left
corner).
Change to the main menu
The operating areas are displayed on

the horizontal softkey bar. The active
"Machine" operating area is green.
Use the appropriate softkey to the

"Program" operating area.
( )
There are various program types which
are now displayed in the softkey bar.
The selected type "Workpieces" (WPD)
is a directory in which all relevant data
of a machining task (part programs,
subroutines etc.) can be stored.
It is thus possible to structure all data
clearly.
53
Create a new workpiece directory for

Longit... the "Longitudinal guide".
Enter the name of the workpiece (there
is no distinction between capital and
small letters).
Please observe that each name can be
used only once. (You have possibly to
choose another name).
At the control system keyboard, text

and digit inputs are always accepted by
pressing the yellow <Input> key, and at
the PC with <Return>.
Because you want to create a workpiece (WPD = WorkPieceDirectory), you can accept
the file type without any changes.
The heart of the machining is the part program.

An appropriate program segment is to be saved in the workpiece directory.
When saved for the first time, the name

of the toll directory is automatically
used.
However, the file type is still preset to
’workpiece (WPD)’.
To open the list of file types, press the

<Edit> button. Select and apply the
type ’program segment (MPF)’.
(MPF = Main Program File)
(Alternatively, you may select the
desired type directly by its initial
letter, "T".)
A template is not used in this case.
54
The editor in which the program is

written is opened.
The name of the workpiece directory is
written in the headline, followed by the
name of the main program.
The first program line is selected.
eof = marks the end of the program
(end of file).
If ... automatic block numbering is active on your control

system.
Programming is to be carried out

without automatic line numbering.
The control runs also without block
numbers and writing of a program is
more convenient without numbers.
You can add block numbers later
automatically via <Renumber>.
Accept the changed setting screen.
... Delete the line number first created automatically.
; Main pro... The semicolon marks a comment line.

To accept each program block, use the
<Input> key ...
If you like, you can specify, e.g. the
used tools in further comment lines....
; Tool list:
; shell end mill 60mm
; ...
An additional space line (by ’Input’) is used for structuring the program.
55
3.1.2 Tool call and tool change

Either you are using a control system Or you are using a control system which
which manages tools with manages tools with T numbers
plain-text names (see Section (see Section 2.2.2).
2.2.1).
T="SM60" ; Shaft milling tool T17 ; Shaft milling tool
The tool (T = tool) is selected with its The tool (T = tool) is selected with its T number which
plain-text name which was assigned was assigned in the tool management (operating area
in the tool management (operating ’Parameters’).
area ’Parameters’). Notice: This case differentiation in the tool
management will later not be explained
once more in detail. Then you have to
change tool call yourself!
M6 With machines equipped with a tool changer, M6 will call the tool change.
3.1.3 Fundamental functions

G17 G54 G64 G90 G94 These are fundamental functions which are explained
more in detail in the following overview:
These functions are often valid for a complete
program. But it is proposed to carry out these funtions
at each tool change.
Description of functions Functions of the same group
G17 - Selection of XY plane G18 - Selection of XZ plane

G19 - Selection of YZ plane
G54 - Activation of first zero offset G55, G56, G57 - further zero offsets
G53 - Cancelation of all zero offsets
(non-modal)
G500 - Disabling of all zero offsets
G64 - Approximate positioning. The target point of
a traversing block is not exactly approached, G60 - Exact stop. The target point is approached
but there is a little rounding to the exactly. To this aim, all axis drives are
subsequent traversing path. decelerated until they stop.
G90 - Programming of absolute dimensions
G91 - Programming of incremental dimensions
G94 - F is used to program the feedrate in mm/min. G95 - F is used to program the feedrate in mm
(per revolution)
The functions of a group cancel each other. To see which functions are currently active, press the
softkey in the operating area ’Machine’.
56
These are the first lines of the program!

The first tool was loaded and important,
general basic settings have been
defined.
This tool with a width of 60 mm will now
be used to rough-mill the slot with a
width of 61 mm.
3.1.4 Simple traversing paths without cutter radius compensation

G0 X110 Y0 In rapid traverse (G0), the tool is moved first to its starting position in the plane XY.
110 = X value of the workpiece edge + cutter radius + safety clearance = 150/2+60/2+5
(The key for accepting a program line is not given here in detail because of better legibility.
Accept each line manually by pressing the key!)
G0 Z2 S600 M3 M8 Before the cutter is traversed to the required milling depth, position it on an intermediate
plane (Z2) above the workpiece surface.
This guarantees safety when starting up the program (if the workpiece zero or the tool
compensation were inadvertently set incorrectly). Furthermore, it is possible to
accelerate the spindle in this block and to turn on the coolant.*
S600 speed S = 600 min-1
M3 tool rotates clockwise (CW rotation)
M8 coolant is turned on
* Caution: All technological data used are only example values. Use your own empirical values
on the machine and observe the information provided in the tool catalog.
GO Z-10 In rapid traverse (G0), the cutter will go

on traversing up to the required
machining depth.
Note:
For reasons of safety, this traversing
path should be realized as a G1 block
with feedrate:
G1 Z-10 F400
57
G1 X-110 F400 The cutter traverses at feedrate

(feedrate 400 mm/min) along a straight
line (G1) to the target point X-110
(absolute dimension referred to zero).
For G91 (incremental dimension),
X-220 would have been programmed
because the cutter traverses by
220 mm in the negative axis direction.
G0 Z100 M5 M9 With rapid traverse (G0), the cutter is

traversed away from the workpiece in
Z direction. At the same time, the
spindle is stopped with M5 and the
coolant is turned off with M9.
Space line for structuring at the end of the machining with the shell end mill
T="EM16" ; End milling cutter D16mm The two edges of the groove
M6 (61 mm in width rough-milled
with a ø60 shell end mill)
will be milled to dimension using the
16 mm end mill.
G17 G54 G64 G90 G94 The same G functions as we had for the first
machining will also be used as the basis for machining
with the end mill.
G0 X85 Y22.5 In this first example, the contour is

G0 Z2 S500 M3 M8 finished without taking into account the
G0 Z-10 cutter radius automatically, i.e. the
center point path of the cutter is
G1 X-85 F200
programmed:
G0 Y-22.5
G1 X85 22.5 = 61/2-16/2
X85 means 2 mm overflow.
With F200, the feedrate is selected less
than before with the shell end mill.
G0 Z100 M5 M9 At the end, the workpiece is left at rapid traverse rate, the spindle is stopped and the
coolant is turned off.
58
Space line for structuring
If ... you only want to mill (not drill), or if you just want to have a closer look at the simulation
then you can end the progam now:
M30 M30 is used to end the part program.

When the program is executed, M30 will cause it to return to the beginning, and it can
be restarted. M30 has therefore always to be written in the last program line.
You can simulate the finished program ... (for

more details, see Section 3.1.7)
... and after quitting the simulation
... execute it in the operating area "Machine" in

AUTOMATIC mode (see Section 2.3.2).
...
To be able to supplement the program later by the drilling machining operations, select
the workpiece directory "LAENGSFUHERUNG.WPD" in the operating area "Program",
open it with <Input>, select the part program and open this with <Input>.
Please make sure that the following program lines (see below: T="CD12" ...) are
inserted before the command M30.
3.1.5 Drilling using cycles and subroutine technique
Centering
T="CD12" ; Center drill 90° D12mm First, all twelve holes are to be centered.
M6
G17 G54 G60 G90 G94 When drilling, G60 (exact stop) is
used in order to ensure a high
degree of dimensional accuracy
for all holes.
59
The holes can be divided into two

groups:
- 4 x M10 thread at the corners
- 2 single holes and
1 circle of holes in the slot
The positions of the first group are later

entered in a subroutine called
THREAD, those of the remaning holes
in the subroutine INTERNAL.
Subroutines are useful here because

the positions are approached both for
centering, as well as for drilling and
thread cutting.
G0 X-65 Y40 The first thread hole is approached at rapid ttraverse with a safety clearance (in the top
G0 Z2 S500 M3 M8 left corner of the screen), and the coolant is turned on.
F150 The input of the feedrate is here not in the G1 block because all traversing paths of
machining are realized in one cycle:
Horizontal softkey for selecting the

main menu ’Drilling’
The associated submenus will then

appear on the vertical softkey bar.
60
The dialog box for the drilling cycle

CYCLE82 (drilling, counterboring)
( ) is opened via the vertical softkey.
The cursor is positioned on the first
input field. The meaning of the field is
explained graphically in the help
screen, and in the yellow headline you
will find an appropriate text.
2 Some of the fields in the dialog box are

already assigned default values.
0
At first, change or supplement the first
1 * three entries according to the values
given in the screenform.
* ... or here (because already loaded
with the appropriate default values)
simply or
According to the drawing, the holes have a diameter of 10 mm and are to have a chamfer
of 1 mm in width. A 90° center drill must therefore be inserted 5.5 mm.
Notice ... This ’final drilling depth’ can be entered in two different ways:
( ) ABS Absolute, i.e. the depth gauge

-5.5 referred to the workpiece zero is
entered.
Here: -5.5 ABS
INC Incremental, i.e. relatively to
( ) ’reference plane’. Because only
5.5 one ’downward’ machining is
useful, a (negative) sign is not
entered for incremental depths.
Here: 5.5 INC
You can also change between ABS and INC with the <Shift> key or with the softkey
[Alternative] if the field ’Final drilling depth’ is selected.
Both input options are correct. The setting INC is, however, recommended for centering
because it is thus possible to center drill holes with one incremental depth on different
reference planes.
61
The dwell time 0 can remain unchanged.

But do not close the dialog box too
quickly because ...
If ... the text ’Drill/CYCLE82’ is displayed in the headline

of the dialog box, the cycle would be called in the
program only once.
In this case you still have to switch over to modal
efficiency.
The entry in the headline changes:

’Drill/MCALL CYCLE82’
’Modal’ means that a command (e.g. a G function, a programmed axis position or, as in this case, a complete
cycle) is effective beyond the block in which it is programmed. In the case of drilling cycles this would mean
that the block would be executed once again after each traversing path programmed after this block.
The cycle is accepted into the program.

If you want to change a cycle block, you
can do this via the softkey [Recompile] .
THREAD ; Subroutine with coordinates You will write the subroutine itself later. At this point it
is just called with its name. At all points approached
in the subroutine, the drilling cycle CYCLE82 is called
because of modal efficiency.
These two softkeys are used to disable the modality of the cycle, and you will quit the
drilling menu.
(Alternatively, you can simply also type MCALL in the text editor. With this procedure, you
will not quit the drill menu. At the end of all drill operations, you will quit it with .)
Select the dialog box for the drilling

cycle once again.
All inputs have been kept
from the first call.
If you have entered the
-10
’final drilling depth’
incrementally (INC), you
have to change only the
value of the ’reference plane’.
62
If ... If you have entered the ’final drilling depth’ absolutely

(ABS), you have to change it here as well.
Final drilling depth absolute =

-15.5 reference plane - final drilling depth
incremental = -10-5.5
Accept the cycle into the program.
INTERNAL ; Subroutine with coordinates Same procedure as with the subroutine THREAD
Same procedure as when centering the 4 thread

holes.
G0 Z100 M5 M9 Retraction from the workpiece; spindle

and coolant OFF.
Empty line for structuring
For verification, the whole program part

for centering at a glance
Tap-hole drilling
T="TD8_5" ; Tap hole drill for M10 thread The threaded holes M10 have a
M6 ø8.5 mm tap hole.
G17 G54 G60 G90 G94 A twist drill is used for
G0 X-65 Y40 drilling.
G0 Z2 S1300 M3 M8
F150
63
Call the dialog box (the same as for

centering) for the drilling cycle and
enter the values.
The final drilling dept should be entered
here absolutely (-23 ABS).
0 The addition of 3 mm to plate thickness
results from the snap formula for taking
into account the point angle of 118°:
( ) "Allowance = 1/3 drill diameter"!
-23
THREAD ; s.a. Call of the subroutine with the positions of the four
holes.
Use these softkeys to disable the modality of the

cycle.
G0 Z100 M5 M9 The known procedure at the end of a machining

procedure.
Tapping
T="T_M10" ; M10 tap
M6
G17 G54 G60 G90 G94 can be omitted here. The feedrate
G0 X-65 Y40 results from the entered speed and the
G0 Z2 S60 M3 M8 thread pitch which is indicated in the
cycle.
Drilling is carried out without compen-

( ) sating chuck ("rigid tapping"). This is
marked by the grey softkey text
"without compensation chuck".
This cycle is also required to be modally
( ) active (see MCALL in the headline).
64
2
0
...
( )
If the entries in the "Table" and
"Selection" fields do not comply
with the given values, you can
switch over with the key .
A higher speed when retracting

saves production time.
THREAD ; s.a. Same procedure ...
... as for the tap hole!
G0 Z100 M5 M9
Drilling through holes ø10

T="TD10" ; Twist drill D10mm Program lines for through holes
M6 INTERNAL
G17 G54 G60 G90 G94
G0 X-50 Y0
G0 Z2 S1300 M3 M8
F150 The drilling cycle is also entered via
MCALL CYCLE82(2,-10,1,-23,0,0) the softkeys and the input dialog.
INTERNAL ; s.a.
MCALL
G0 Z100 M5 M9
65
If ... If the drilling menu is still active

(because you entered the line MCALL
instead of creating it via the softkeys...)
... you can return to the higher-level

menu by pressing the <Recall> key.
The part program is stored, and you will

return to the program management.
66
3.1.6 Creating a subroutine

(Vertical softkey in the program
management in the "Program"
operating area, see previous page)
THREAD The first subroutine is given the name

THREAD (see call in part program).
The file type "part program", however,
is set by default.
Use the <Edit> key to open the list

of the file types. Select the type
"Subroutine" and accept!
(SPF = Sub Program File)
(Alternatively, you can select the
required type via the first letter "s".)
The subroutine is created and the

editor is opened.
Now, write the program...
G0 X-65 Y40 The four positions of the threaded

G0 X65 Y40 holes are approached with G0 blocks
G0 X65 Y-40 at rapid traverse.
G0 X-65 Y-40 The modal efficiency of the cycles in the
part program has the effect that the
appropriate cycle is executed after
each G0 block (see page 62).
67
M17 M17 marks the end of a subroutine

(cf. M30 at the end of a part program).
Back to the program management

Both part program (MPF) and
subroutine (SPF) are parts of a
workpiece (WPD).
Use the same procedure to create the

subroutine INTERNAL ...
INTERNAL
G0 X-50 Y0 ... and write the NC block for the

first position.
The circle of holes is entered as

already machining via a dialog
box.
Additional information:
By the way: It would have been

possible to enter all the other
positions also in this way (see
softkey [Arbitrary position]). This is a
question of the programming
style - as with ABS and INC.
68
Circle The position pattern includes a

0 name under which it could be
repeatedly called in different
0
places.
20
All dimensions result from the
... drawing.
Accept the inputs of the dialog box into the program.

The lable name "circle:" and the line "ENDLABEL:"
frame the position pattern and form thus an own
subroutine.
G0 X50 Y0 Add the last drilling position and M17

M17 for the subroutine end.
Back to the main menu of the editor
Back to the program management
... Now mark again the main program

(type "MPF")
(LONGITUDINAL_GUIDE) ...
69
... and open it with the <Input> key.
3.1.7 Simulating a program

The simulation graphics is created and
the workpiece is shown in top view (see
softkey with the ***türkisfarbenenem***
margin).
Workpiece zero and workpiece

dimensions, however, do not yet
correspond to the program to be
simulated.
Use the appropriate softkey to open
the interactive screenform for the
simulation settings.
Enter the blank dimensions

(coordinates of the corner points)
-75
of the cuboid.
75
Xmin -75 Ymin -50 Zmin -20
... Xmax 75 Ymax 50 Zmax 0
Accept the settings.
70
The workpiece dimensions are now

correct.
Start the simulation!
If ... you want to track a part of the

simulation very exactly ...
then use the softkey [Single Block] to switch to single block simulation.
The simulation will stop after each block; to continue, press [NC Start].
...
Pressing [Single Block] once more lets you return to subsequent block simulation.
You can relocate a certain part with the < Arrow Keys>, and with <+>/<-> you can zoom it.
By using [Override] and <+>/<-> or

arrow keys, you can influence their
speed during simulation.
3D presentation at the end of the

simulation.
71
To quit the simulation press this softkey or the <Recall> key ( ).
To quit the editor press the appropriate softkey.
The file DPWP.INI is created automat-

ically. Among other settings, it includes
the customer’s settings for the
simulation of the "Longitudinal guide".
Section 2.3.2 decribes in detail how you load the program into the NC main memory in
order to be able to start it afterwards in the AUTO mode in the "Machine" operating area
for machining.
72
3.2 Workpiece "Injection mold"

Using the workpiece "Injection mold" as an example, you will become familiar with the functions of the
control systems for path milling and pocket milling. We take it for granted that you have already
processed the example "Longitudinal guide" or are familiar with the subjects discussed in this context.
This chapter will deal with the following new subjects:
• Arcs
(dimensioned using both Cartesian
and polar coordinates)
• Milling with workpiece radius

compensation
• Rectangular pocket
(roughing and finishing)
• Circular pocket
• Copying of a program part
3.2.1 Creating workpiece and part program

( ) Initial status:
( ) • "Program" operating area
( ) • Workpiece management
( )
(same procedure as for the workpiece
"Longitudinal guide" in Section 3.1)
73
3.2 Programming: Milling - Workpiece "Injection mold"

INJECTION_MOLD the "injection mold".
Create the part program for the

workpiece "injection mold".
...
The program was created and the

editor opened.
(If necessary disable the automatic
block numbering via / <Settings> /
... / ; see Section 3.1).
; Injection mold with path milling and pockets Comment line as the program header
74
3.2.2 Straight lines and arcs - path milling with cutter radius compensation
The material is to be shaped by cutting
along the contour marked in blue by
means of a 20mm end mill.
The contour is to be approached at
point A.
Milling is carried out synchronously,
the cutter rotating CW traverses around
the contour in CW direction.
The distances to be traversed including

retraction and approach paths along
the contour are entered here directly in
the editor (as a basic exercise).
Of course, you could also enter the
contour with the graphic contour
calculator in a subroutine (cf. contour
of the turned part "Complete") and
program the machining with the cycle
CYCLE72 ([Milling] > [Path milling] ...).
T="EM20" ; End mill D20mm Tool call (configuration

with tool management)
M6 Workpiece change
G17 G54 G64 G90 G94
Basic settings
(see Section 3.1.3)
G450 CFTCP G450 defines the approaching behavior at the starting point of the contour and the
behaviour when traversing along contour corners: As far as contour corners are
concerned, the appropriate traversing or approaching movements are carried out along
a circular path.
CFTCP (acronym for "Constant Feed Tool Center Path") defines that the programmed
feedrate refers to the cutter center-point path (not to the contour).
These commands (and of course all the other) are described in detail in the online help,
which you can call - as described in the following - if your control system possesses a
hard disk:
75
... Simply position the cursor on the

command on which you want to get
more information.
Then press to get a short
description and once again to open
the electronic programming manual.
You can navigate within the manual via

the softkeys, and afterwards you can
quit it again.
G0 X-12 Y-12 A point near the starting point A on the

contour is approached as the starting
position of the cutter in the XY plane.
G0 Z2 S1500 M3 M8 Infeed motion in Z, speed, direction of rotation and

coolant ON
G0 Z-5 Outside the workpiece it is possible to infeed to the
milling depth at rapid traverse rate (or better at
feedrate: G1 Z-5 F100, see page 57).
G1 G41 X5 Y5 F100 The contour is approached ... *

* A tangential approach of the point via an intermediate point at X5/Y6-12 (with G41 active)
would be better in view of the manufacturing technology. The procedure selected here
(angle between approaching path and first contour straight line < 180°, i.e. starting point
before the contour) is normally easier as regards the program: If the first contour element
is not paraxial, the exact intermediate point must be calculated.
See also the "intelligence" of the approaching strategy using G450/G451 and the option of
processing with the path mill cycle CYCLE72 ([Milling] > [Path milling] ...), generating
approach and retract paths.
76
G41 turns on the cutter radius compensation.

The programmed coordinates (X5/Y5) do not refer to
the cutter center point path in case if compensation is
turned on, but to the contour.
G41 means: The cutter is -
viewed in the traversing
direction - left of the contour.
A traversing path with the tool

right of the contour would be
programmed with G42:
G1 X5 Y75 First traversing path along the contour:

Vertically to Y75
G2 X25 Y95 I20 J0 G2 - arc CW:
X,Y Absolute dimensions of the end

point E
I Distance between A and M in
X direction
J Distance between A and M in
Y direction
I and J are the incremental center point
coordinates of the arc, referred to the
starting point A.
Alternatively, it is also possible to define the

arc via the radius (CR = Cycle Radius): In this
case, however, an equality sign has to be
entered between the address CR and the
value (here 20) :
G2 X25 Y95 CR=20
{arcs > 180° (dotted line) would be program-

med with a negative radius value
(CR=-20).}
G1 X120 Horizontal line at X120
77
The following is known from the

following arc:
Center point P
Distance RP between the center point
(the pole) P and the end point E
Angle AP between the positive X axis
of the path from P to E
G111 X120 Y75 G111 is used to enter the (absolute!) coordinates of the center point (of the pole).
G2 RP=20 AP=4 The dimensions of the distance RP (radius polar) and the angle AP (angle polar) in the
following G2 block are entered with an equality sign!
G1 X145 Y5 Line G1 to the bottom right contour

corner
G1 X-12
Line G1 bypassing starting and end
points of the contour and away from the
workpiece.
At the corner formed by the two straight
lines, the command G450 just
programmed results in a compensating
arc of the cutter center path.
(Alternatively, G451 would extend the two straight lines of the cutter center path up to
the intersection point.)
G0 G40 Y-12 G40 - cancel cutter radius compen-

sation
Because the cutter is already outside
the workpiece, the radius compen-
sation can be carried out at rapid
traverse. The position X-12/Y-12 will
then refer to the cutter center point
again.
G0 Z100 M5 M9 Retraction from the workpiece; spindle

and coolant OFF
78
For checking the whole program part of

path milling at a glance
3.2.3 Rectangular pocket POCKET3

The rectangular pocket requires a
smaller cutter due to the corner
radius R9.
At first, the pocket is to be roughed
at the bottom and at the edge with an
allowance of 0.3 mm, followed by
finishing.
Both can be realized with the help
of the rectangular pocket cycle
(POCKET3) ...
T="EM10" ; End mill D10mm Tool call

M6 Tool change
G17 G54 G60 G90 G94
Basic settings
G0 X75 Y50 At rapid speed to the pocket center

G0 Z2 S2000 M3 M8 Infeed at safety clearance, speed, direction of
rotation, coolant ON
79
Roughing the rectangular pocket

F200 Although the feedrate F is defined within the pocket cycle, it is advisable to program it
already in advance: The value already defined in the cycle is no longer valid after the
end of the cycle; it could be possible that any following "single" traversing blocks G1,
G2, G3) would unintentionally traverse at the feedrate of the previously programmed
machining operation.
As the drilling cycles for the workpiece "Longitudinal guide", the input screen for the
rectangular pocket cycle is called via softkeys. To open the submenu on the vertical
softkey bar, use the softkey in the main menu.
2 The input fields for the pocket cycle go

0 beyond the display area of the dialog
box.
1
You can navigate within the dialog box
( ) via the scrollbar on the right or with the
-15 arrow keys.
For the other entries (CRAD, etc.),
( )
please refer to the two screenshots on
( ) the left.
60 When selecting the maximum infeed depth
MID, the safety clearance has been taken
40
into account up to Software Version 5.2.
... The 15.7 mm resulting from pocket depth,
safety clearance and finishing allowance
are distributed equally. An infeed of 3 x
5.233 mm is carried out whereby a plunge-
cut of of 4.233 mm is carried out during the
first cut.
With Software Version 5.3 and higher, it is
sufficient to have an infeed depth of 5; the
infeed is 3 x 4.9 mm.
Independent of the software version you are
using, you will be on the safe side with
6 mm.
Press this softkey to accept the cycle into the program.
In the text editor, the cycle appears as follows:
80
Finishing pocket edge and pocket bottom

After having carried out the roughing cycle, the cutter returns to the starting point of the
machining. The same cutter is used for finishing.
S2400 F160 Speed and feedrate for finishing.
Because you still are in the menu ’Standard

pockets’, after roughing you can call the dialog
box for the rectangular pocket directly via the
softkey.
All fields still contain the values you

... have entered for roughing. The input
fields have therefore only to be
changed ...
Machining: .........Finishing
... Infeed depth MID: .........16
Feedrate surface.FFP1: .160
Feedrate depth FFD: ....80
16
... Notice: The values for the two finishing
dimensions are kept by the roughing
cycle. The finishing cycle calculates the
infeed motion from the finishing
allowance and the safety clearance.
Milling is finally carried out to the
nominal size.
Press this softkey to accept the finishing cycle into the program.
According to version and screen resolution, differences might occur in the presentation
of the cycles in the editor. It is therefore recommended to use the "Recompile" function
to carry out any changes in the cycle paramaterization.
81
3.2.4 Circular pocket POCKET4

All four circular pockets are identical,
apart from their position.
At first the circular pocket in the bottom
left corner is to be programmed.
The other three pockets will be
generated by copying and changing
the first one.
S2000 F200 Speed and feedrate for machining the pockets.
Select the dialog box for the circular pocket.
2 Milling to size (in two steps):
0 - Machining "Roughing"
- Infeed dimension ... *
1 - No finishing dimension
( ) All inputs can be found in the
illustrations on the left.
-10
( )
15
25
25
...
Press this softkey to accept the cycle for the first circular pocket into the program.
82
Now it would be possible to call the dialog box for the second circular pocket cycle with
the softkey [Circular pocket]. As already described in the beginning, another procedure
will be exercised here.
Quit the menu for pocket milling.
3.2.5 Copying a program part

The cycle for the circular pocket has
been accepted into the program. The
cursor is now in the next (empty) line.
Position the cursor on the program line

with circular pocket POCKET4.
Press the vertical softkey [Mark block].
The cycle is marked with a different

color and the softkey appears inversely
(white on ***türkis***).
83
Use the appropriate softkey to copy the

cycle into the buffer memory.
Move the cursor back into the next

(empty) line and insert the cycle from
the buffer at this place.
Repeat inserting twice for the third and

fourth circular pockets.
Four identical circular cycles will be the
result.
84
Now you have only to adapt the parameters for the

position of the pocket with the three copied cycles.
The softkey [Recompile] recompiles the cycles shown
cryptically in the text editor again to the presentation
of the dialog box.
Based on the first pocket in the bottom left corner, the

other pockets are to be machined clockwise.
• The pocket in the top left corner is at X25/Y75 ...
... Select the second cycle.
"Recompile" the cycle and

... change the value "center point
PO".
75
Press this softkey to accept the changed cycle for the

second circular pocket into the program.
• The pocket in the top right corner is at X120/Y75 ...
Select the third cycle.
Make intentionally a mistake when entering the value

... ’center point PA’ and "forget" the "0" of "120". This
mistake will be referred to for the simulation on the
12
next page.
75
Press this softkey to accept the changed cycle for the

third circular pocket into the program.
85
• The pocket in the bottom right corner is at X25/Y75 ...
... Select the last cycle..
"Recompile" the cycle and change the value ’center

point PA’.
...
120
Press this softkey to accept the cycle for the fourth

circular pocket into the program.
Then position the cursor on the next empty line.
G0 Z100 M5 M9 The machining operation is finished: Retract from the workpiece; spindle and coolant
OFF!
M30 End of program (if not yet written beforehand).
Call of the simulation to check the

programming
The workpiece ’Injection mold’ has

another zero point than the workpiece
... programmed before.
The corners of the unmachined cuboid
have therefore to be adapted:
Xmin 0 Ymin 0
Xmax 150 Ymax 100
86
Start the simulation.
If ... If you detect a mistake in the

simulation like here in case of
the third circular pocket
incorrectly positioned, then:
stop the simulation, ...
... and activate the editor for correction.
The cursor is then directly in the line in

which you quitted the simulation (in this
case at the third circular pocket).
87
... Correct the mistake, ...
... and change again to the simulation

with [Close editor].
Simulation, here in the two-sides

presentation (top view and front view)
Press this softkey or the <Recall> key ( ) to close the simulation.
Press this softkey to quit the editor.
Later it will be explained more in detail how to load the

program into the NC main memory in order to be able
to start it afterwards in the mode ’AUTO’ in the
operating area ’Machine’ for machining (Section
2.3.2.)
88
Notes
89
4.1 Programming: Turning - Workpiece "Shaft"
4 Programming: Turning
In this chapter you will learn how to program the control systems
SINUMERIK 810D/840D/840Di, using the example of two simple
sample turned parts.
What we told already in the "milling chapter" also applies here: The
sample programs are only intended as an entry to give you a first
overview as regards the programming possibilities of the control
system.
If you have some experience, you can

optimize the programs later according
to your own requirements.
When dealing with the second shaft,
you will learn something about the SINUMERIK
contour calculator and functions for complete machining.
4.1 Workpiece "Shaft"

Using the workpiece "Longitudinal guide" as an example (blank ø80, length 101), you learn the complete way
from the drawing to the finished NC program key by key. The following topics will be discussed:
• Structuring into workpiece, part and

subroutine
• Subroutine technique for contour
description and approaching of the
tool change point.
• Tool call, constant cutting speed,
fundamental functions
• Face turning
• Cutting cycle CYCLE95
• Finishing with tool radius compen-
sation
• Thread undercut cycle CYCLE96
• Thread cycle CYCLE97
• Grooving cycle CYCLE93
90
4.1.1 Creating workpiece and subroutine

Initial status:
• Any operating area (here
"Machine") and mode (here
"AUTO")
• Channel status RESET, i.e. no

program is currently executed. If
( )
not yet done, press the <Reset>
key to reset the control system
(see status bar in the top left
corner).
Change to main menu
The operating areas are displayed on

the horizontal softkey bar. The active
"Machine" operating area is highlighted
Use the appropriate softkey to change

to the "Program" operating area.
( )
There are various program types which
are now displayed in the softkey bar.
The selected type "Workpieces" is a
directory in which all relevant data of a
machining task (part programs,
subroutines etc.) can be stored.
It is thus possible to structure all data
clearly.
91

SHAFT the "SHAFT".
Enter the name of the workpiece (there
is no distiction between capital and
small letters).
Please observe that each name can be
used only once. (You have possibly to
choose another name.)
When working with the control system

keyboard, text and numerical inputs are
always accepted by pressing the yellow
<Input> key, and when working on the
PC - with <Return>. The "File type" field
receives the focus.
Because you want to create a workpiece (WPD = WorkPieceDirectory), you can accept
the file type without any changes.
An entry window will again appear for

saving files in the workpiece directory.
The name "SHAFT" was taken from the
workpiece directory and ’Workpiece-
(WPD)’ can again be seen in the ’Data
type’ field.
CONTOUR You want to enter the turning profile in

a subprogram.
First overwrite the name with
"Contour", the name of the
subprogram.
Enter it by pressing on <Input>.
92
Use the <Edit> key to open the

directory of the file types. Mark and
accept the type "subprogram"!
(SPF = Sub Program File)
(Alternatively, it is also possible to
select the desired type directly via the
first letter <s>).
A template is not used.
This editor in which the subroutine is

written is opened automatically.
The name of the workpiece directory is
written in the headline, followed by the
name of the program. The first program
line is selected.
eof = marks the end of the program
(end of file).
93
If ... If automatic block numbering is active on your control

system ...
Programming is to be carried out

without automatic line numbering.
The control runs also without block
numbers and writing of a program is
more convenient without numbers.
You can add block numbers later
automatically via [Renumber].
Accept the changed setting screen.
... Delete the line number first created automatically.
G18 G90 DIAMON G18 defines the XZ plane as the machining plane (default for turning). G90 defines that
all coordinates are entered absolutely, i.e. referred to the workpiece zero point.
DIAMON means "Diameter ON", i.e. the X values are entered exclusively with reference
to the diameter (independently of G90/G91).
Alternatives: DIAMOF ..... Reference to radius ...... independently of G90/G91
DIAM90 Reference to diameter... with G90 active (abs. dimens.)
Reference to radius........ with G91 active (incr. dimens.)
The line is closed with <Input>. The cursor goes to the next line. (This key will not be
explained in detail once again).
The commands for the face turning of

the workpiece at Z0 will later be entered
in the main program.
The subroutine starts with a G1
G1 X24 Z1 command to a starting point in the
extension of the chamfer 2x45°.
Please note: The X value refers to the
diameter!
94
G1 X30 Z-2 Approaching the contour of X24/Z1 and

the machining of the 45° chamfer can
be done in one block.
The turning tool traverses in X and Z by
3 mm each to the programmed position
X30/Z-2.
The G1 command from previous blocks is "modally effective". This means that all
subsequent blocks would traverse as straight lines, also without writing G1. (G1 will only
be canceled by a command for an arc G2/G3 or a rapid traverse movement). But G1 is
here always written because of clarity.
G1 Z-20 Horizontal skimming of the thread rated

diameter.
The X value 30 will be maintained from
the block programmed before, i.e. it is
"modally effective".
The thread undercut will later be
programmed as an independent cycle.
G1 X40 RND=2.5 Vertical on X40. The transition to the

G1 X50 Z-30 oblique line at X50/Z-30 will be rounded
with 2.5 mm (RND = Rounding).
95
G1 Z-44 RND=2.5 Program the other traversing paths along the contour!
CHR=1 generates a chamfer between the straight lines with a width of 1 mm.
G1 X60 CHR=1
(A chamfer whose length has been dimensioned would be programmed with the
G1 Z-70 RND=1
command CHF.)
G1 X66 RND=1
G1 Z-75 RND=1
G1 X76
G1 X82 Z-78 Chamfer and tangential leaving of the

contour
M17 M17 marks the end of the subroutine.
The whole subroutine at a glance

Some program lines in the diagram on
the left include comments.
Comments in the program are marked
by preceding semicolon.
The character marks the end of a line.
Of course, this contour could also

have been entered using the contour
calculator (cf. contour of the turned
part "Complete").
96
The subroutine is stored, and you will

return to the program management.
Depending on the configuration of your

control system, you can also store your
program in the meantime via softkey, or you
will be asked when closing it whether you
want to store the program.
Use the same procedure to create a

subroutine "TCP".
TCP
This subroutine will later carry out the
S
approach to the tool change point and
is called at each tool change.
G0 G18 G40 G500 G90 X400 Z600 T0 D0 G97 S300 M4 M9 Copy these two program lines! At the
M17 end of the first line, press to accept
them. At the same time, the cursor will
go to the next line.
It is traversed...
- at rapid traverse (G0),
- in the XZ plane (G18),
- with the tool radius compensation deselected (G40)
- in the machine coordinate system (G500)
- to the absolute position (G90) X400/Z600.
This position refers to the toolholder (T0 D0). The tool compensations are disabled.
Because the axes of some machines are only traversed when the spindle is rotating,
the speed (G97 S300) and a direction of rotation (M4) have to programmed. The coolant
is turned off (M9).
M17 marks the end of the subroutine.
Store the subroutine by closing the editor.
97
4.1.2 Tool call, cutting rate and fundamental functions
SHAFT The part program "SHAFT" is created.
TCP ; Move toolholder to change point Selection of the subroutine for appproaching the tool
change point and optional comment.
Depending on how your control system is configured, there are different ways how to call the tool:
Either you are using a control system or you are using a control system which
which manages tools with manages tools with T numbers
plain-text names (see (see Section 2.2.2) ...
Section 2.2.1)
T="RT1" D1 ; Roughing tool 80° R0.8 T1 D1 ; Roughing tool 80° R0.8
The tool (T = Tool) is selected The tool (T = tool) is selected with its T number which
with its plain-text name has been assigned in the tool management (operating
"Roughing 1" which has been as- area ’Parameters’). This number corresponds to the
turret location of the tool (here: location 1) .
signed in the tool management
(operating area "Parameters") Notice: This case differentiation in the tool
management will later not be explained
once more in detail. Then you have to
change tool call yourself!
98
G96 S250 LIMS=3000 M4 M8 G96 enables the constant cutting rate, i.e. the cutting
tool cuts - independent of the diameter on which it is
located - by 250 m/min (see Section 1.2.3). Because
the speed would be infinite, a limit speed is always
programmed together with G96 (LIMS for limit speed),
here 3,000 1/min.
M4 defines the direction of rotation CCW (viewing
direction "back from the chuck") .
M8 turns on the coolant.
G18 G54 G90 These are some further fundamental functions which will be explained more in detail in
the following overview. These functions often apply to a whole program ("modal
efficiency"), and they can be written in the program header once. But it is better to
implement these functions at each tool change.
This is especially true for the complete machining on turning machines where several
technologies (turning, drilling, milling) occur on different machining planes in
combination.
Description of functions Decsription of functions of the same group
G18 - Selection of the XZ plane G17 - Selection of the XY plane

G19 - Selection of the YZ plane
G41 - Tool radius compensation left of the contour G42 - Tool radius compensation right of the contour
G40 - Selection of tool radius compensation
G54 - Activation of the first G55, G56, G57 - Further zero offsets
zero offset G53 - Cancelation of all zero offsets
(non-modal)
G500 -Disabling of all zero offsets
G90 - Programming of absolute dimensions G91 - Programming of incremental dimensions
G94 - Linear feedrate in mm/min
G95 - Revolutional feedrate in mm/rev. (default for milling)
(default for turning; with G96 active, G95 is
enabled automatically) G97 - Constant speed
G96 - Constant cutting rate (for drilling and milling operations)
(for turning)
The functions of a group cancel each other. To see which functions are currently active, press
the softkey in the "Machine" operating area.
99
These are the first lines of the program.

The toolholder is at the change point,
the first tool has been loaded and
important general basic settings have
been defined.
The workpiece will now be faced with
the roughing tool.
4.1.3 Face turning

G0 X84 Z0.2 At first, the cutting tool is moved at rapid
traverse (G0) from the tool change
point to a position 2 mm above the
workpiece.
0.2 mm allowance is taken into account
at the face side for finishing.
The key for accepting a program line is
not given here in detail because of better
legibility. Accept each line manually by
pressing the key!)
G1 X-1.6 F0.32 Facing is realized at feedrate.

When doing so, the tool traverses in the
X direction according to the cutter
radius across the turning center
(negative X-value):
Cutter radius 0.8 times 2 for the
diameter coordinate: X-1.6
G0 Z2 Retraction from the workpiece

G0 X80 Intermediate point near the starting point for subsequent roughing cycle.
The starting point itself is calculated by the control system. Because it could be
approached from the current position Z2 without collision, the block G0 X80 Z2 is only
intended for better legibility of the program or for safety reasons in the case of program
changes. It can also be dropped.
100
4.1.4 Cutting cycle CYCLE95

The main menus are on the horizontal
softkey bar.
By pressing the softkey [Turning] you
can see submenus for the various
turning cycles on the vertical saftkey
bar.
The dialog box for the cutting cycle

CYCLE95 is opened by pressing the
vertical softkey.
The cursor is positioned on the first
input field. The meaning of some fields
is explained graphically in the help
screen, and in the yellow headline you
will find an appropriate text.
The name of the contour subroutine
must be entered in the first field.
CONTOUR Change or supplement the entries

... according to the values given in the
screenform.
Select here the rough-machining
"roughing".
Finishing will later be carried out
separately simply by running the
subroutine "CONTOUR".
The cycle is accepted into the program.
101
Press the <Recall> key to quit the menu with the

turning cycles.
If you want to change a cycle block later, you can do
this via the horizontal softkey [Recompile].
TCP Call of the subroutine for approaching the tool change

point.
An additional empty line at the end of machining with

the cutting tool serves for structuring.
4.1.5 Finishing
T="FT1" D1 ; Finishing tool R0.4 Tool call
G96 S320 LIMS=3000 M4 M8 Cutting rate for finishing
320 m/min
G18 G54 G90 Fundamental functions for machining
G0 X32 Z0 Face turning of end face to size

G1 X-0.8 F0.1 X-0.8 considers the cutting radius R0.4
G0 Z2 Retracting from workpiece
G0 G42 X22 Z2 Approaching near the starting position for the finishing
traversing paths of the subroutine "CONTOUR".
At the same time, G42 enables the tool radius
compensation right of the contour.
CONTOUR Call of the subroutine that contains the finishing

contour
G0 G40 G91 X2 At the end (here to exercise once incrementally with

G91 and DIAMON) 1 mm are removed from the
workpiece.
At the same time, the tool radius compensation is
turned off (G40).
If ... you want to simulate the progam...
M30 The simulation expects the command M30 for marking the end of the program. The
simulation would take place even without M30, but then an error message would be
provided. It is therefore recommended to write M30 before the simulation is called for
the first time.
102
Call the simulation screenform.
The workpiece dimensions normally do

not yet correspond to the program to be
simulated.
Press this softkey to open the dialog

box for the simulation settings. Enter
the blank dimensions (diameter and
80 length):
... Outer diameter: 80

Z-min: -100
Z-max*: 1
* Allowance for facing
Accept the settings.
Press the softkey [NC Start] to start the

simulation.
You can change between single and

subsequent block simulation with
[Single Block].
Various views are offered to choose
from.
Finally, quit the simulation window with

the <Recall> key.
Please note that the following program
lines must be inserted before the
command M30.
103
4.1.6 Error correction - parallel editing of main program and subroutine

If ... If you have detected an error in
the simulation which is to be
found, e.g. in the subroutine
"CONTOUR" ...
Quit the simulation with <Recall> key.
Use the extended softkey bar to load

the subroutine "CONTOUR" as the
second file into the editor where you
... can change it.
In this case, the minus sign of the

Z value was obviously forgotten.
... The missing minus sign was inserted.
Please note that any changes in this

second file are not accepted automa-
tically.
First, the file has to be stored per
softkey.
104
You should also make sure that the

main program ("SHAFT.MPF")
receives the focus again before the
... simulation is called once again.
In this respect it is not important for
starting the simulation in which line of
the program the cursor is.
If there still is an error in the simulation, you should generally use the <Recall> key to
quit the simulation window and not [Program correct.] since the latter function only allows
the editing of the main program.
( ) If, finally, the subroutine is correct, position the focus on the subroutine window and
close it with the softkey.
4.1.7 Thread undercut acc. to DIN76

After you have carried out the
"digression" as described in Section
4.1.6, you should now have the only
main program in the editor.
G90 The traversing path in the last block was programmed incrementally (G91).
Use G90 to switch over to absolute programming!
G0 Z-10 A position is approached at rapid

traverse from which the starting
position of the undercut can be reached
wihout crash.
F0.07 Feedrate 0.07 mm/revolution
105
Select the appropriate softkeys to call

the input window for the undercut cycle.
A distinction is made between form E
and F (according to DIN 509) and form
A,B,C,D (for thread undercuts
according to DIN 76).
( ) If necessary, use the softkey to switch

over to [Form A,B,C,D].
... A thread undercut FORM B is to be

turned at nominal diameter 30 and
reference point Z-20.
Press this softkey to accept the cycle into the

program.
Quit the menu "Turning".
G0 X82 Z2 Approaching a safe intermediate position and

TCP approaching the tool change point
An additional empty line for structuring
106
4.1.8 Thread cutting cycle CYCLE97

After the undercut, the thread M30 is
turned.
According to the standard, the undercut
is 9 mm in width. The dimension is
given in brackets in the diagram just for
orientation.
T="Thread" D1 ; Thread cutting tool Tool call

G96 S200 LIMS=3000 M3 M8 Technological data: In
order to produce a
right-hand thread, the
cutting tool has to be
installed "the other way
around" in the turret.
G18 G54 G90 Thus, the spindle has
to rotate clockwise (M3).
G0 X40 Z7
Fundamental functions
At rapid traverse from the tool change point near the
starting point for threading cycle.
According to the standard, an M30 thread has a pitch
of 3.5 mm. General rule for the thread run-in path:
approx. 2 - 3 x pitch (2 x pitch was selected here)
107
( ) Enter the values for the threading

cycle.
According to the standard, some
30 values result from the nominal
dimension.
The inputs for the thread pitch PIT and
...
the thread depth TDEP are thus
implemented automatically.
End point and run-in path are added
resulting in a traversing path in Z to -17.
Using the simulation, you can check
whether this dimension is correct. But
consider also the actual geometry of
the cutting tool.
... The last two last entries in the input

window "scrolled" down.
Use these softkeys to accept the cycle

into the program and to quit the
program.
G0 X40 Approaching a safe intermediate

TCP position and movement to the tool
change point.
The screenshot shows the program
overview for the last two working steps
(thread undercut and thread).
Call of the simulation to check the cycle
Use the arrow keys <+>/<-> to zoom

the area in which the thread is
machined.
Start of the simulation

The machining of the thread is represented
... using a different color. The selection of the
colors can be configured via [Settings] >
[Display & colors ...].
108
4.1.9 Grooving cycle CYCLE93

Then produce two undercuts.
To do so, use the procedure already
known:
• Tool call
• Technological data
• Fundamental functions
• Rapid traverse
positioning
near the
T="GT_3" D1 ; Grooving tool 3mm, left cutt. edge
first plunge-cut
G96 S200 LIMS=3000 M4 M8
G18 G54 G90 • Feedrate
G0 X64 Z-40 • Cycle call
F0.05
Enter the values for the first plunge-cut.
In this respect, the following is to be

observed:
...
In the fields "Radius / chamfer", a
negative sign indicates that "chamfer"
has been chosen.
A chamfer can be defined either via its
width or its length. The selection "CHR"
defines that the entries are interpreted
as "chamfer width": (according to the
dimensioning in the drawing 1x45°).
The interrelation between the two fields

"selection" and "starting point" is shown
in the following help screen:
109
Press this softkey to accept the cycle into the

program.
All entries from the plunge-cut last

created are kept.
In this case, you have only to change
-64
the value for the "starting point SPL"
for the second plunge-cut.
Use this softkey to accept the cycle into the program

Use tis softkey to quit the "Turning" menu.
G0 X82 Retraction from the workpiece

TCP Traversing to the tool change point
The whole part program once again at a glance!

Any changes in the "normal" program lines can be carried
out directly in the text editor. If you want to overwrite parts
of the program, activate the softkey [Overwrite].
For changes in a cycle you should move the cursor into the
appropriate line and then you should open the input window
of the cycle with the softkey [Recompile].
If you want to change the sequence of machining, e.g.
plunge-cutting first, then proceed as follows:
Position the cursor on the first character of the relevant
program block (i.e. on the ’T’ in the line T="GT_3" D1).
Then press the softkey [Mark block].
Use the arrow keys to move the cursor down and then to
the right on the last character of the block (i.e. on the ’P’ in
the line "TCP").
Then press the softkey [Copy block].
Position the cursor on the place in the program you want to
edit and then press [Insert block].
Finally, select the block in the original place in the program
once again and delete it there using the softkey [Delete
block].
Store the program with [Close editor] and return to
program management.
The steps required to execute the program on the
machine are described in Section 2.3.2.
110
4.2 Workpiece "Complete"

Using the workpiece "Complete" (blank ø90, length 101) as an example, you will learn - apart from a
repetition of the "classical" turning machining which has already been discussed using the example of
the "shaft" - further elementary and useful aspects of the control system:
• SINUMERIK contour calculator for

the simple input even of complex
contours with graphics assistance
• Concentric drilling on the turning
machine
• Eccentric machining of the end face
with the function TRANSMIT (with
driven tools)
• Hole circle cycle HOLES2
4.2.1 The SINUMERIK contour calculator

( ) As already exercised using the

example of the "shaft", create a new
( )
workpiece directory and give it the
( ) name, e.g. "COMPLETE".
( )
Create there a subroutine with the
name "CONTOUR".
...
If necessary, see Section 4.1.1.
You are now in the editor and could try

to enter the contour with G functions as
for the "shaft".
But it is much easier with the graphical
contour calculator ....
111
4.2 Programming: Turning - Workpiece "Complete"
The user interface of the contour

calculator consists of three parts:
• The contour definition is
represented by small icons on the
left of the column. At the beginning,
only the symbols for the starting
point and the contour end exist.
• In the middle the contour definition
will be built up dynamically as a
graphics during the input. So you
always have a visual control of your
inputs.
• These are made via input fields as
you already know them from the
cycles.
40 The contour definition starts 1 mm in X

1 and 1 mm in Z before the first contour
point.
Note: It may happen that with the
software version of your control system
Z must be programmed before X (and
with arcs correspondingly K before I)
for reasons of compatibility!
All dimensions in the X direction refer
to the ’diameter (DIAMON)’.
Accept the starting point.
Instead of thinking in cryptic

G commands, you can also create the
contour definition using simple
pictographs (see vertical softkey bar).
112
It starts with an oblique line...
48 ... to the (absolutely dimensioned) end

-3 point
X 48.000 abs
Z -3.000 abs
The angle to the positive X axis
α1 = 135.000 °
... is calculated and displayed automa-
tically. In addition to the graphics, you
can use this display also as an input
control.
Accept the first contour element.
A horizontal line follows. This is indicated by a dotted

line.
The end point Z is not known.

The input field remains empty.
( )
The ’transition to the following
4 element’, the arc R23, is rounded with
R4 .
If necessary use the <toggle key> or
the softkey [Alternative] to switch from
’FS’ (chamfer) to ’RD’ (radius) and
enter the value.
Accept the partially defined contour element. The Z

value of the end point (?) will later result from the
construction of the subsequent arc R23.
113
Call the input window for arcs:
( ) In addition to the direction of rotation

and the radius, the diameter value of
23
the end point is also known:
60 X 60.000 abs
... and the absolute coordinates of the
80 center point
-35 I 80.000 abs *

K -35.000 abs *
* The meaning of I and K as the center point coordinates in X and Z is illustrated in the
help screen which you can call up with the key if the cursor is positoned on I or K.
Pressing lets you return to the online graphics.
( ) After the input of R, X, K and I, the arc

is determined such that it can also be
represented in the graphics as a dotted
line.
Now you can choose between two
mathematically possible end point
coordinates in Z (-14.288 or -55.712).
Select the alternative where the point
at Z-55.712 is marked in black.
Accept the dialog.
( ) Furthermore, it is to be decided
whether the transition between the
horizontal line and the arc will be at
Z-20 or only at Z-50 (see diagram).
Select the alternative at which the black

line corresponds to the drawing.
Accept the dialog.
114
If ... you have made a mistake in the

dialog selection ...
... you can call it again using this softkey

and change it.
Switch the presentation of the input

parameters to [All parameters].
This presentation displays all
coordinates of the arc both absolutely
and incrementally (the entered values
are black, the calculated grey).
In addition to the coordinates, the angles of the arc are also calculated and displayed:
α1 Starting angle referred to the positive Z axis
α2 Starting angle referred to the previous element (here the horizontal line)
β1 End angle referred to the positive Z axis
β2 Aperture angle of the arc
The starting angle of the arc is important for the subsequent production which (without
taking into account the rounding) decreases towards the X axis by less than 46°.
The exact angle taking into account R4 could also be determined if R4 would not be
entered as a rounding, but as an "independent" contour element with tangential
connections (softkey [Tangent prev.elem.]) to the horizontal line and the arc R 23. This
leads to a starting angle R23 of about 42°.
When selecting the tool in the main program, take into account that the clearance angle
of the tool to the Z axis is greater than this starting angle of the arc (in this regard, see
also Section 2.2 "Setting up", page 39).
115
4 Do not forget to enter that the arc also

changes into the following horizontal
straight line with a rounding of 4 mm.
Accept the element.
Let’s continue horizontally:
-75 The theoretical end point of the straight

line is at ...
Z -75.000 abs
6 It is rounded with
RD 6 .000.
Accept the element.
An oblique line follows:
90 "Theoretically", it ends at
-80 X 90.000 abs
Z -80.000 abs
4
and is rounded with ...
RD 4 .000.
Accept the element.
116
A horizontal line forms the end:
Not the dimension of the blank length

is interesting for the machining, but the
Z value up to which the machining
-85 takes place.
With...
Z -85.000 abs
... you are on the safe side when
rounding.
Accept the element.
Explanations on the topic "Transition

radius or tangential transition"
Apart from the chamfer at the beginning,
everywhere in this contour definition there
are "soft" (also tangential) transitions
resulting from a transition radius to the
following element. At the theoretical
transition point between the main elements,
however, the connection is not tangential
(left diagram).
Use the softkey for a transitional
Remember: arc only if you cannot enter it as a rounding
due to its dimensioning (right diagram).
Either Element 1 with ’RD’
or Element 2 with [Tangent prev.elem.]
If ... you want to change an element

of the contour later ...
... you can navigate in the toolbar with

the <arrow keys>
... and open the input dialog for the
respective element with <Input>.
...
117
Accept the complete contour definition

into the editor.
Go with the cursor to the end of the line ...

... and with <Input> into a new line.
M17 Add the command M17 which marks

the end of the sub-program.
If ... you want to change contour definition later ...
... position the cursor to any program line of the

contour definition and press the softkey [Recompile].
Do not change any values in the text editor because
this might make it impossible to recompile later!
...
Store the subroutine by closing the editor.

(Depending on the configuration of your machine,
there is also a separate softkey for saving [Save file]
on the vertical softkey bar.)
118
4.2.2 Cutting and finishing of the contour with undercut

Now create the subroutine "TCP.SPF"
TCP for approaching the tool change point
and the part program
... "COMPLETE.MPF" in the same
directory.
COMPLETE
...
The content of the subroutine is

identical to the appropriate program for
the "shaft".
The first lines of the part program differ

only a little bit from the beginning of the
program "Shaft" in Section 4.1:
Since the contour of the workpiece
"Complete" contains an undercut 35°
plates are used (and a correspondingly
large clearance angle).
"RT2" R0.8 "FT2" R0.4
Other than in the first example, the

same roughing tool is used for facing to
size (Z0).
Feedrate and cutting depth will be
adapted accordingly.
Input fields for the cycle CYCLE95 (see

selected line in the editor) called via the
softkeys [Turning] and [Cut]
119
4.2.3 Drilling centrally

; Drill centrally After turning, the
T="SD16" D1 ; Solid drill D16mm through-hole is to be
produced using a
G97 S1200 M3 M8 16 drill.
Drilling is carried out at

constant speed (G97). Unlike turning, the spindle
rotates clockwise (M3).
G17 G54 G90 G95 Plane selection G17* for machining on the end face, activation of zero offset G54,
absolute programming G90, feedrate in mm/rev G95
* For drilling centrally, the machining can generally also be programmed in the G18
plane. But when doing so, please note that the length compensation changes:
G17: length1 in Z (as for milling) G18: Length3 in Z !!!
G0 X0 Z2 The workpiece is approached at rapid traverse rate. Later, when executing the program,
make sure that there is no collision with the tailstock!I
Drilling is carried out at feedrate through the workpiece having a length of 100 mm (with
G1 Z-105 F0.1 an allowance of 5 mm).
G0 Z2 The drill is retracted from the workpiece at rapid traverse.

TCP Finally, the subroutine "TCP" (tool change point) is called again.
Calling the simulation to check the programming ...

... and automatic adaptation of the ’Settings’ (blank
... ø90, length 101)
By using <arrow keys> and <+>/<->,

you can "zoom" the area in which you
are especially interested.
Simulation of turning and drilling
...
120
4.2.4 End face machining with TRANSMIT

More and more turning machines provide the possibility of milling or drilling end or peripheral faces by using
driven tools.
Your SINUMERIK control system naturally also supports such technologies. The programming for a drill
pattern at the end face is presented here as an example.
; Hole circle on end face Comment line for better legibility of the program.
G54 G64 G90 G94 Fundamental G functions

G18 Plane selection
SPOS=0 Spindle positioning (C axis) on 0°
T="TD5" D1 ; Twist drill D5mm Tool call
SETMS(2) Spindle 2 (the spindle driving the tool) becomes the

so-called "master spindle").
S2=1000 M2=3 Speed and direction of rotation of the second spindle
are entered with an equals sign (see S1000 M3 for
the main spindle of the machine).
TRANSMIT This function (Transform Milling Into Turning) carries out transformation of the axes for
milling and drilling at the end face.
The following traversing movements can be carried out in the Cartesian coordinate
system (X,Y) as generally used for milling. The control system will then convert these
program blocks for the real axes (X,C). The Z axis remains unchanged.
(The appropriate function for peripheral face machining is called TRACYL).
DIAMOF From now on, the the X values refer to

the radius.
G17 The XY plane will be selected as the
machining plane. Please note that the
axes X and Y are turned by 90°,
compared with milling.
G0 X15 Z2 Approaching near the starting point for
the first hole. As necessary observe the
position of the tailstock.
F140 Feedrate in mm/min (see G94)
The deep-hole drilling cycle CYCLE83

is used here once again as an
excercise.
121
... Complete the input fields.
The cycle is to be called at four

positions, i.e. it is to be modally
effective (cf. workpiece "Longitudinal
guide when milling").
To take into account the drill tip, approx.
1/3 x tool ø is added to the final drilling
depth.
The positions of the drill pattern can

also be created via a cycle ...
... Complete the input fields.

(The help screen is static; in reality, the
axes are turned by 90°.)
Accept the drill pattern into the program.
Instead of the cycle one could also have programmed

the 4 drill positions via simple G0 blocks (cf. milling
example "Longitudinal guide"). Now the compen-
sation of both methods as they appear in the editor:
MCALL The "MCALL" command will cancel the modal efficiency of the drill cycle.
122
TRAFOOF The transformation function TRANSMIT is disabled again.

DIAMON The following X values refer to the diameter again.
SETMS(1) The main spindle becomes the "Master spindle" again.
TCP Approaching the tool change position

M30 End of program
Simulation in the 2-side view which you

can call via the softkey .
... In the screen shown on the left, it has

been switched to the presentation of the
tool paths with .
By using , you can switch the

focus between the two simulation
windows, zooming the images
separately.
Quit the simulation graphics
Close the editor to save the program.
On the following page you can find again an overview of the whole part program.
123
124
Notes
125
Appendix
Index
A End of subroutine ...................................... 69, 97

ABS ................................................................... 62 Exact stop ......................................................... 60
Absolute dimension ......................................... 59 F
Absolute dimensions ................................... 8, 11 Feedrate ........................................................... 59
Angle ............................................................. 9, 12 Floppy disk ....................................................... 44
Aperture angle ............................................... 115 Following block ................................................ 72
Approach behavior G450 ............................... 76
G
Approaching strategy ...................................... 77
G-Funktionen ............................................. 57, 99
Arc ..................................................................... 78
Archive directory .............................................. 44 H
Archive file .................................................. 47, 47 Hard metal ........................................................ 14
Area switchover ............................................... 20 Help screens ...................................................... 6
Hole circle cycle ............................................... 70
C
Cancel cutter radius compensation .............. 79 I
Cartesian ............................................................ 9 INC .................................................................... 62
Chamfer CHR/CHF ................................. 96, 109 Incremental dimension .................................... 59
Changing the contour definition .................. 118 Incremental dimensions .............................. 8, 11
Changing the machining sequence ............ 110 K
Channel status ................................................. 28 Keyboard .......................................................... 23
Clearance angle ...................................... 40, 115 Keys ................................................................... 23
CNC full keyboard ........................................... 23
L
CNC keyboard ..................................... 23, 23, 23
Loading the magazine .................................... 33
Comment line ................................................... 56
Lochkreiszyklus ............................................. 122
Comments ........................................................ 96
Compensation values ..................................... 38 M
Coolant ................................................. 58, 59, 97 Machine ............................................................ 20
Creating a subroutine ..................................... 68 Machine control panel ...................18, 18, 23, 23
Creating a tool ........................................... 30, 35 Machine zero M ................................................. 7
Cutter radius compensation ........................... 78 Magazine list .............................................. 30, 30
Cutting edge ..................................................... 32 Modal efficiency ......................................... 63, 68
Cutting edge position ...................................... 40 O
Cutting rate S ................................................... 13 Offset values ........................................ 32, 32, 32
CW rotation ...................................................... 58 online help ........................................................ 76
D Operating area ................................................. 28
Deep hole drilling cycle ................................ 121 Operating area "Parameters" ......................... 20
Diagnosis .......................................................... 21 Operating area "Program" .............................. 21
Diameter reference DIAMON ........................ 94 Operator panel front ........................................ 18
DIN keyboard ................................................... 24 P
Direction of rotation ......................................... 97 Parameters ....................................................... 20
DPWP.INI ......................................................... 73 Part programs ............................................ 54, 91
Drilling cycle CYCLE82 .................................. 62 Path feedrate .................................................... 76
E PC keyboard .................................................... 23
End angle ....................................................... 115 PC keys ............................................................. 23
End of program .............................................. 102 Plunge-cutting cycle CYCLE93 ................... 109
Polar .............................................................. 9, 12
126
Pole ....................................................................79 Training keyboard ..................................... 23, 23

Program ................................................ 21, 21, 21 Turning off .................................................. 23, 23
Program status .................................................28 Turning on ........................................................ 19
Programmiergerät ............................................44 Type number .............................................. 37, 37
Q Type of tool ...................................................... 36
QWERTY keyboard .........................................24 U
R Undercut ......................................................... 119
Radius compensation ......................................32 Undercut cycle CYCLE94 ............................ 106
Radiusbezug DIAMOF ....................................94 W
Recompile .......................................................118 Working planes .................................................. 5
Recompiling ....................................................110 Workpiece directory .................................. 54, 91
Reference point approach ..............................19
Referenzpunkt ....................................................7
Roughing cycle CYCLE95 ............................101
Rounding RND .................................................96
S
Schneidenradius ............................................100
Scratching .........................................................41
Screen layout ............................................. 28, 28
Services .............................................................21
Setting zero .......................................................41
Simulation ........................................ 71, 108, 120
Simulation speed ..............................................72
Single block .......................................................72
SinuTrain .................................................... 19, 19
Slimline operator panel ............................ 23, 23
Softkeys .............................................................28
Speed ................................................................97
Starting angle ..................................................115
Start-up ..............................................................22
Subroutines ................................................ 54, 91
T
Table book ........................................................15
Tangential transition ......................................117
Technological data ...........................................17
Thread cutting cycle CYCLE97 ....................107
Tool axes .............................................................5
Tool call ...................................................... 57, 98
Tool change ......................................................57
Tool compensation .................................... 29, 29
Tool list ....................................................... 31, 31
Tool management ............................................29
Toolbar .............................................................117
Tools in the turning programs ........... 40, 40, 40
127
Behandelte Befehle
Commands and addresses
und Adressen
discussed in this Manual Cycles discussed
A J Drilling cycles
AP= 78 J 10, 77 CYCLE82 61
CYCLE83 121
C K
CFTCP 75 K 13, 114 Milling cycles
CHF= 96 POCKET3 80, 81
CHR= 96 L POCKET4 82
CR= 77
LIMS= 16, 99
Turning cycles
D M CYCLE93 109
D 38, 98 CYCLE94 106
M2= 121
DIAMON 6, 94 CYCLE95 101
M3 57, 107, 120
DIAMOF 6, 94 CYCLE96 106
M4 99
DIAM90 94 CYCLE97 107
M5 58
M6 56
F M8 57, 99 Position cycles
F 15, 17, 58, 100 M9 58, 97 HOLES2 69, 122
M17 68, 69, 96, 97, 118
G M30 59, 86
MCALL 62, 123
G0 57, 100
G1 58, 100
G2 10, 13, 77 R
G3 13 RND= 96, 118
G17 5, 6, 56, 99, 120, 121 RP= 78
G18 6, 56, 99, 120
G19 6, 56, 99 S
G40 78, 102, 119
S 14, 16, 57, 97, 99, 120
G41 76
S2= 121
G42 102, 119
SETMS( ) 121, 123
G53 56, 99
G54 39, 40, 56, 99
G55 56, 99 T
G56 56, 99 T 56, 98
G60 56, 99 T=" " 56, 98
G64 56, 99 TRANSMIT 121
G90 8, 11, 56, 99 TRACYL 121
G91 8, 11, 56, 99 TRAFOOF 123
G94 56, 99
G95 56, 99, 120 X
G96 16, 99 X 5, 57, 94, 121
G97 16, 120
G111 78
G450 75, 76
Y
G451 75, 76 Y 5, 57, 121
For a description of all commands and
cycles of the control system, please refer
I Z to the user documentation
I 10, 13, 77, 114 Z 5, 57, 94 "Programming Guide - Fundamentals".
128
Reference of photos and illustrations
We would like to express our special thanks to
DMG
Europa-Verlag
Iscar
Reckermann
Sandvik
Seco
for making available the photographs on the pages 14, 15, 16, 17, 38 and 39.
http://www.ad.siemens.de/jobshop
http://www.siemens.de/sinutrain
Siemens AG
Automatisierungs- und Antriebstechnik
Motion Control Systems
Postfach 3180, D - 91050 Erlangen
Siemens Aktiengesellschaft Order No.: 6FC5095-0AB00-0BP1

SIN Ein

Uploaded by

Copyright:

Available Formats

SIN Ein

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SIN Ein

Uploaded by

Copyright:

Available Formats

SINUMERIK 810D/840D/840Di

Beginner’s Manual: Milling and Turning

All rights reserved

This Beginner’s Manual has been created in cooperation of

Order No.: 6FC5095-0AB00-0BP1

Erlangen/Wuppertal, in March 2001

1.1 Geometric fundamentals of milling and turning

1.1.1 Tool axes and working planes

Tool axis Z - working plane G17

Tool axis Y - plane G18

Note: It may happen with the software

Rotating axis Z - plane G18 *

Use the key to call approriate help screens to select the

The radius dimension

* All turning operations are programmed in plane G18.

Toolholder reference point T

1.1.2 Absolute and incremental dimensions (milling)

Absolute inputs: Incremental inputs:

End point End point

*G90 Absolute dimensions *G91 Incremental dimensions

1.1.3 Cartesian and polar dimensions (milling)

All hidden values are

Angle 53.13° = starting angle to positive X axis

Cartesian and polar inputs can be combined, e.g.:

1.1.4 Circular movements (milling)

Input of the center point (absolute):

After input: After input:

The inputs of the arcs in the text editor would be:

1.1.5 Absolute and incremental dimensions (turning)

Absolute input: Incremental input:

Using the softkey , you

End point End point

*G90: Absolute dimensions *G91: Incremental dimensions

Two examples of the combination absolute/incremental:

1.1.6 Cartesian and polar dimensions (turning)

End point End point

Angle 126.87° = starting angle to positive Z axis

1.1.7 Circular movements (turning)

Input of arc R10: Input of arc R20:

After input: After input:

The inputs of the arcs in the text editor would be:

1.2 Technical fundamentals of milling and turning

1.2.1 Cutting rate and speeds (milling)

Cutting tool material grade: Workpiece material:

vc = 80 ... 150 m/min:

Calculating the speed:

115mm ⋅ 1000- 115mm ⋅ 1000-

1 1 (in the workshop also often referred to

1.2.2 Feedrate per tooth and feedrate (milling)

Determining the feed per tooth:

Feed per tooth fz = 0.1 ... 0.2 mm:

Determining the feedrate:

The NC coding uses the acronym "F" for the feedrate.

1.2.3 Cutting rate and speeds (turning)

Cutting tool material grade: Workpiece material:

Constant speed n (G97) when drilling and thread cutting:

1.2.4 Feed (turning)

Determining the feed:

Cutting tool material grade: Workpiece material:

G90 Absolute dimensions G91 Incremental dimensions

G90: Absolute dimensions G91: Incremental dimensions